Apparatuses and Systems for Growing Nursery Stock

ABSTRACT

The present invention is directed to, a container, multiple arrangements of container and flat/tray pallets, corresponding container/flat/tray/pallet assemblies, an automated pallet assembly/disassembly system, autonomous pallet assembly transfer units, an autonomous pallet assembly transport train, and an integrated automated production system, for use in a horticultural nursery environment for: substantially reducing labor needed to produce; stabilizing of; collecting and shedding broadcast applications to; reflecting desired sunlight to foliage of; reducing root tip heating of; reducing water consumption in growing; reducing wetting of foliage of; controlling excess root growth of; and, reducing weed growth proximal to; spaced potted plants.

RELATED APPLICATION

This application claims the benefit of priority to U.S. provisionalpatent application Ser. No. 60/646,846, entitled “Apparatuses andSystems For Crowing Nursery Stock,” which was filed in the United StatesPatent and Trademark Office on Jan. 25, 2005, and is incorporated byreference herein.

FIELD OF THE INVENTION

The present invention relates generally to a system, a container, acontainer mounting structure, and a container mounting assembly. Moreparticularly, the invention is directed to an automated productionsystem, a container, a container pallet, and a container pallet assemblyfor use in a horticultural nursery environment for: reducing laborneeded to produce; stabilizing, collecting and shedding broadcastapplications to; reflecting desired sunlight to foliage of; reducingroot tip heating of; reducing water consumption in growing; reducedwetting of foliage of; controlling excess root growth of; and, reducingweed growth proximal to; spaced potted plants.

BACKGROUND OF THE INVENTION

The nursery industry supplies ornamental crops to the consumer by way oflarge nurseries, which grow the crop for the landscaping and gardencenters where consumers and landscapers acquire their plants forplanting in consumer's yards.

The nursery industry is a multi-billion dollar industry in the US, withmore than 20,000 nurseries nationwide. Evidence suggests that hisindustry, like many, also conforms to the 80/20-rule, in that 80% of allornamentals are grown by 20% of all growers nationwide. Plants can besegregated into shrubs and trees, the former of which is almostexclusively grown in plastic containers, and the latter grown both incontainers and in the ground (known as ball-and-burlap or B&Bnurseries). Container nurseries represent about 60% of the nurseryindustry, while the B&B portion accounts for the remainder.

Plants grown in containers can be shipped directly to the market withoutthe need for transplanting. Container grown plants produce numerousadvantages to the nursery by reducing labor cost, as well as handling,packaging and other operating costs. In addition, growing plants incontainers provides comparatively simplified weed control and enablescontrolled irrigation and fertilization.

Container nurseries range in size from a few acres to a few thousandacres, where the larger nurseries typically comprise operations atmultiple sites. Some nurseries specialize in certain varieties whileothers grow many varieties of plants. Many nurseries clone their ownvarieties, propagating them, prior to planting them in containers andgrowing them in the field. Once plant material has sufficiently matured,it is sold to other nurseries, distributors, landscape contractors,and/or retail stores. Some nurseries specialize exclusively inpropagation, while others only grow containers—nurseries might evenspecialize in growing certain ornamental varieties for a short period oftime, before reselling them to other nurseries for further maturingbefore they are resold to the general public.

Container nurseries are located in different growing regions across theUS, largely where climate benefits the type plant material grown. Plantsare grown in greenhouses and in the field, as needed to provide aproductive growing environment for the plant material. In order tomaximize the usage of acreage, nurseries in the regions with frost andsnow utilize greenhouses in which plants are grown over the winter.

Growing plants in containers does, however, have several disadvantages.While production labor content is, indeed, reduced throughcontainerization of the plant material, substantial production labor isstill necessary.

Virtually all container nurseries utilize seasonal immigrant labor,typically from Mexico, in order to meet their production needsthroughout the growing seasons. Such labor is getting more difficult toobtain, requiring continued lobbying-effort in Washington, D.C. toguarantee exemptions from the Immigration & Naturalization Service(INS), involves costly recruiting south of the border, transportation toand from their hometowns and their accommodations once in the US andworking on site. In addition, the allure for workers to perform tiringand backbreaking work outdoors is fading when the same labor pool isbeing sought for other better paying and lower exertion jobs in the USeconomy such as assembly, custodial and other such job categories.Recently, the State of California has actually banned hand weeding ofmost crops due to worker back injury issues.

A large portion of labor-intensive tasks in container nurseries involveshandling of containers. Containers are typically repotted before everygrowing season, requiring them to be picked up in the field, placed ontrailers, brought to a potting shed where they are taken out of theircontainers and repotted in a larger container with additional soil (socalled up-shifting), placed on trailers, driven out to the designatedbed (usually an outdoor field area), where they are then placed back onthe ground in a variety of different tight/staggered/spaced patterns toallow the plants to grow during the season. The plants are alsofertilized and continually watered when in the field. Growers in frigidregions also need to take plants out of greenhouses and perform theup-shifting and spacing operations. All these operations are extremelylabor intensive and need to be performed in as compressed a time aspossible. Competing for time (typically mostly in early spring) isshipping of finished plant material, which generates the revenue for thenursery. This involves selecting plants, transporting them to theshipping dock and loading trucks. In the case of nurseries in the ‘snowbelt’, containers that were placed in the field need to be moved intogreenhouses, requiring another intensive labor effort to pick them fromthe field, transport them via trailer to the greenhouses, and tightlypack them inside the structures to survive the winter months.

The degree to which growers and laborers perform their jobs efficientlyhas a large impact on the nursery's profit margin and its ability tooptimize plant growth and health. Since production labor is theprevalent cost in growing ornamentals (up to 20% to 35% of salesaccording to large growers), the potential for increasing thecompetitiveness of the industry through automation in order to reducemanpower requirements, or even smooth out the peak labor requirements,is potentially very large.

Schempf in U.S. Patent Application No. 20020182016 presents results of asurvey taken of growers, which provides us a distribution of nurseryproduction labor over various production-related tasks, as follows(where no. 1 rank implies the highest number of laborers required):

1. Moving containerized plants to the canning shed from the growing bedsand from the growing beds to the potting shed.2. Moving containerized plants from the growing beds to the staging(shipping) area.3. Spacing the containerized plants in the growing beds.4. Moving containerized plants into and out of the over-winteringhouses.5. Moving containerized plants for pruning plants.6. Moving excess containerized plants during spacing operations.7. Other miscellaneous tasks (including potting, weeding, spraying, andfertilizing).

One need for production labor that challenges growers due to itsunpredictable nature is that associated with returning overturnedcontainerized plant material to its normal upright condition followingwindstorms. Particulate fertilizer applied to the surface of the soil inthe plant containers is spilled on overturning of plant containers. Suchspilled fertilizer, which is often a substantial amount in total acrossthe nursery, is often washed away by rain, rendering it an unrecoverableloss and adding substantially to nursery pollutant runoff. Even if thespilled fertilizer remains on the ground adjoining the overturnedplants, labor to recover it and return it to the plant containers issubstantial.

Uncontrolled overturning of containers also can damage the associatedplant material and create the potential for spread of disease.

Other disadvantages of growing free-standing containerized plantmaterial involve irrigation and other broadcast application of chemicals(fertilizer, pesticide, herbicide, etc), whether liquid or solidparticulate in nature. The soil mixture used for container grown plantsusually has poor water retention so that irrigation must be regularlycarried out to prevent the roots from becoming too dry. Such irrigationis typically accomplished by broadcast sprinkling, which results in themajority of applied water missing spaced plant containers. In mostcases, spilled irrigation water flows to a retention pond where it canbe reclaimed and reused. However, costs of electrical or other energy torun the one or more pumps that typically supply the spilled irrigationwater is not recovered. Costs associated with wear of the irrigationsystem delivering the spilled water are also not recovered. Further,water losses still occur due to evaporation and percolation of at leastpart of the spilled irrigation water as it runs downhill along its drainpaths to the retention pond, particularly in dry locales of relativelylow humidity, where the water is needed most and is, thus, typicallyrelatively expensive. Further still, reclaimed water, potentiallyoriginating from many areas within a nursery, has the potential tospread disease.

Disadvantages similar to those of broadcast irrigation apply also tobroadcast application of chemicals. Spillage of such materials furtherpotentially contributes adversely to pollution in nursery site runoff,particularly following rain sufficient to cause overflow of thenursery's one or more retention ponds.

Beeson, Haman, Knox, Smajstrla, and Yeager in U.S. Pat. No. 6,415,549present a plant container and container attachment yielding afunnel-shaped container upper opening for collecting otherwise spilledirrigation water and for attachment to adjoining like containers forincreasing container orientation stability. The container attachment,while relatively effective at collecting otherwise spilled irrigationwater, contemplates substantial additional labor for implementation,which quickly negates water savings.

In addition, above ground containers of containerized plants are oftenin direct sunlight and wind, which contribute to rapid waterevaporation. Most containers used by wholesale nurseries have thin wallsand are constructed of plastic containing carbon black, an ingredientthat promotes high container longevity, but makes the containers blackin color and, thus, highly absorbent of impinging sunlight's radiantenergy. The thin side wall(s) of the container thus become hot in directsunlight and can scorch root tips approaching the container side wall(s)on the inside, adversely affecting the plant growth potential. Aboveground containerized plants in more northern regions are also subject tofreezing temperatures that combine with high winds to cause convectiveheat losses by the containers sufficient to freeze roots ofcontainerized plants, potentially killing the plants.

To minimize these disadvantages associated with container grown plants,many nurseries anchor or bury the containers in the ground. This reducesthe risk of the roots freezing and the plant from blowing over in highwinds. A significant disadvantage of buried containers is the difficultyof removing the container from the ground before the plants can beshipped. Moreover, the roots from the plant grow outward through thedrain holes in the container into the surrounding soil. This increasesthe amount of effort required to remove the container from the groundand usually results in root damage to the plant. An example of this typeof growing system is shown in U.S. Pat. No. 5,007,135. This growingsystem provides a sufficiently large opening in the container toencourage the roots to grow outwardly into the surrounding soil. Ashovel or other tool cuts the roots enabling removal of the containerfrom the ground, inherently resulting in damage to the root system.

In recent years, many nurseries have used a below ground system where anempty container is buried in the ground and a growing containercontaining the plant is placed in the buried container. This system isoften referred to in the industry as a pot-in-pot system. The system hasseveral advantages over other growing systems. In particular, thepot-in-pot type system provides protection for the roots to resistfreezing and from drying out in the sun. In addition, the buriedcontainer anchors the plant container and reduces the risk of the plantsfrom overturning in high winds.

As in other below ground growing systems, the roots from the growingcontainer often grow outward from the drain holes into the below groundcontainer. The below ground container is required to have drain holes toprevent excess water from remaining in the container which willotherwise cause the roots to rot, potentially killing the plant. Oftentimes the roots from the growing container will grow outward through thedrain holes of the below ground container and into the surrounding soil.When this occurs, it is difficult to remove the growing container fromthe below ground container since the containers are now tangled with theroot system. In extreme like situations the growing container cannot beseparated from the below ground container without removing bothcontainers from the ground and cutting the roots. This disadvantageincreases the labor costs and damages the root system of the plant.

Another disadvantage of in-ground pot-in-pot systems is a lack of meansof collecting and funneling broadcast applications to the containerizedplants, resulting in costs of broadcast application spillage or ofincreased labor for direct application to the containerized plants.Low-flow drip irrigation systems are often used on larger suchcontainers, but necessitate substantial labor for setup.

Another disadvantage of in-ground pot-in-pot systems is the potentialfor the ground in which said systems are mounted to have poorpercolation, resulting in significant retention of rainwater in saidpot-in-pot system and associated resulting rot of roots of incorporatedcontainerized plants, reducing yield.

Another disadvantage of in-ground pot-in-pot systems, particularly ingrowing smaller plant material, is the lowering of potted plant foliageto a point nearer the ground, where it either must compete with proximalweeds for sunlight or may be damaged by weed eradication equipment,wherein such weeds tend to grow in soil exposed through breeches in orin the absence of typical plastic weed prevention sheeting material bythe socket pots, increasing labor and weed control chemicals.

Another disadvantage of in-ground pot-in-pot systems, particularly ingrowing smaller plant material, is the relatively close spacing of opensocket pots needed to maximize bed space utilization, such spacingresulting in awkward and potentially hazardous manual interaction withbed due to the plurality of essentially open holes in the bed.

Another disadvantage of in-ground pot-in-pot systems is the tendency forsocket pots to become at least partially filled with clippings and otherdebris following crop harvest, resulting in additional labor to clearsuch debris for proper nesting and drainage of subsequently incorporatedcontainerized plants.

Schempf in U.S. Patent Application No. 20020182016 offers an example ofa machine for semi-automatically transferring containerized plantsbetween a bed and trailer in the interest of reducing nursery productionlabor. However, significant labor is still required for a portion of theproposed container handling operation and to address machine mishandlingof containers, which Schempf, in related reports, indicates affectbetween 0.4% and 2.3% of containers handled, i.e., typically at leastone container out of every 250.

Examples of various plant growing containers are disclosed in U.S. Pat.Nos. 6,038,813 to Moore et al, 4,106,235 to Smith, 5,279,070 toShreckhise et al, 5,099,609 to Yamauchi and 1,665,124 to Wright andItalian Patent No. 681968 and French Patent No. 427,391. These patentsdisclose plant container systems having a plant container and areceptacle container for receiving the plant container and holding waterfor supplying water to the plant. U.S. Pat. Nos. 5,515,783 to Peng,4,232,482 to Watt et al, 4,027,429 to Georgi and 1,533,342 to Scheindisclose growing containers having a tray or other container below theplant container for collecting water. These containers do not provide asystem for preventing the roots of the plant from becoming entangledwith the other container.

Accordingly, there is a continuing need in the industry for improvedcontainerized plant growing system that overcomes the abovedisadvantages.

SUMMARY OF THE INVENTION

The present invention is directed to an automated system, a container, astructure, and a method, for improving the effectiveness of growingmultiple containerized plants and, particularly, a simple free standingstructure for supporting in upright orientations multiple containerizedplants in planar arrays on a generally horizontal surface, as well asautomated machinery for transporting, handling, assembling, anddisassembling such structure assemblies.

Said pallet comprises a generally horizontal upper wall portion having atwo-dimensional array of downwardly extending receptacles eachsubstantially matching the shape of a container for receipt by each saidreceptacle, said container for holding soil and a live plant. The centerof bottom wall of receptacle further opens to a hollow protrusionextending downward from said receptacle bottom wall, to a closed bottomwall that contacts the surface on which pallet rests, said protrusionforming a column, which with other like columns, collectively supportpallet and contents. Said columns provide for effective spacing ofbottom of supported container a short distance above pallet installationsurface, providing for air pruning of roots growing from container drainholes, improved drainage of containers mounted in pallets sitting on alow, ill-draining mounting surface, and for lifting of pallets frombeneath bottoms of containers mounted in pallets.

Said container has at least one side wall coupled to a bottom wall, andat least one drain opening through said at least one side wall and/orthrough said bottom wall. Said container which may be cylindrical orfrustal in shape may further have an annular groove in its bottom wall,concentric with the container vertical centerline, for engagement with acomplementary lifting device, facilitating container handling stabilityduring pallet assembly and disassembly processes. Such a groove alsoprovides for improved container water retention when combined withstrategic placement of container drain holes.

Unitization of containerized plant material yields a pallet assemblyhaving low height relative to its plan area or footprint, thus achievingsignificant increase in stability relative to like containerized plantmaterial standing free. Such a unitized pallet assembly significantlyresists movement in the face of wind forces as well as transportundulations. Thus, the probability is much greater that a unitizedpallet assembly will remain standing in the same location andorientation for a significant period of time, relative to free-standingplant material. Such stability, without the need for ground-penetratinganchors or receptacles, makes flexible, automated handling andprocessing of palletized plant material economically feasible.

Said upper wall portion further substantially blocks direct sunlightimpingement on side of each said container, reducing sunlight heating ofwall of said container and consequent adverse heating of proximal rootsin said container. Said reduced sunlight heating of container sides alsoreduces the rate at which soil in the container dries and, thus, reducesvariation in moisture from the center of the container to its sidewall(s), and, thus, reducing the characteristic differences between soilin the container and soil in the ground. This presents a more naturalgrowing environment for the containerized plant. Said upper wall portionfurther substantially blocks sunlight needed for weed growth around saidcontainers, reducing the need for herbicide or weed-pulling labor andthe associated costs. Said upper wall portion is further contoured asmultiple, contiguous funnels concentric with and terminating in saidcontainer receptacles, for collecting and shedding broadcastapplications to upper surfaces of soil of said containerized plants insaid containers, significantly reducing spillage of said broadcastapplications. Contouring of said upper wall portion along with propercolor and finish of its upper surface further promotes reflection ofdesired sunlight onto foliage of said containerized plants, enhancingphotosynthesis and associated growth of said containerized plants.

Bottom wall of container receptacle is also elevated to reduce groundcontacting area of said structure, substantially reducing adverse forceson structure assemblies resulting from impact of proximal movingaccumulated rainwater against lower portion of said structure.Incorporation of elevated container platforms also reduces the potentialfor uncontrolled root rot otherwise resulting from containers sitting onintermittent low ground where pools of water may persist well beyondoccurrences of rain showers.

Further, tapered geometry of said structure ensures it nests closely,quickly and easily in a stack of said structures and denests quickly andeasily from a stack of said structures. Further, said structure providesphysical guidance features for quick, simple, consistent installationand removal of said containerized plants, and for mechanized operationsinvolving said structure.

Thermoforming/trimming is the preferred construction method given thethin-wall nature of the structures and the value added fromincorporation of two-layer sheet material. Thermoforming process mayfurther incorporate integral compression molding, providing closecontrol and thinning of selected walls of structure, e.g. for producingintegral spring-loaded hinges at funnel spout portion inlets needed foringress and egress of mounted containers in one style of structure.Structures could also be injection molded of a single color material,with a potential subsequent coating operation applying a second colorachieving a result similar to thermoforming of two-layer material.Construction could also be of formed sheet metal with separatelyattached—either plastic over-molded or equivalently sprung hinged spoutsin one style of structure. Preferred plastic would be tough andrelatively rigid, typical of polyethylene terephthalate (PET), and maybe of post-consumer or post-industrial waste to keep costs low. Carbonblack will preferably be incorporated to the primary, structural, layerto improve resistance to ultraviolet light. A light-colored upper layeris incorporated to achieve the desired light reflectivity. Stamped,sheet metal construction is of corrosion-resistant composition or has acorrosion-resistant coating.

This invention further contemplates pallet manipulation/handling,assembly and disassembly by automatic machinery comprising; a centralpallet assembly/disassembly system, a pallet assembly transport train,and one or more pallet assembly field and/or greenhouse transfer units.A first embodiment of a central pallet assembly/disassembly systemfurther comprises two pallet stacking/destacking units, twocontainerized plant/pallet assembly/disassembly units (PAU's), a palletassembly transport train central transfer unit, a pallet/grid washingunit, a pallet/grid accumulation unit, interconnecting pallet conveyors,and two container indexing/spacing conveyor lines, and, optionally, apallet assembly semi-automatic weeding conveyor line. The central palletassembly/disassembly system is arranged in a loop, enabling palletassemblies of a first type to be removed from a pallet assemblytransport train, associated plant material removed from said pallets ofa first type and loaded into pallets of a second type, and palletassemblies of the second type returned to same pallet assembly transporttrain. Additional processes, e.g., automated or semi-automated potting,automated pruning/shaping, and/or automated, semi-automated, orautomated weeding, may be incorporated into containerized plant conveyorloop handling plant material between points of plant material removalfrom said first and installation into said second pallet types. Mostsystem components further operate bi-directionally, giving rise to aplurality of combinations of operating modes best suited to nurseryseasonal production needs.

Such a system comprises servo-driven components with programmable motionand logic controls—including sensors and transducers for detecting andmeasuring, machine component and product positions—to achieve a highdegree of flexibility. Variations in processed product combinations areaccommodated by stored recipes of machine motion sequences, which,preferably are selected automatically by a central, enterprise-wide,inventory control/master scheduling computer/software system. Such amaster control system directs the assembly/disassembly system and allother autonomous field machinery through radio digital command/feedbacklinks. Real-time kinematic global positioning system (RTK GPS)technology, which provides positioning accuracy to one centimeterhorizontally and 2 centimeters vertically through radio signals fromsatellites and a base station, provides primary machine position andattitude measurements required by autonomous machinery operating in thefield. For autonomous machine operation in areas not having requisiteGPS satellite line-of-sight, e.g. in covered central palletassembly/disassembly area, conventional buried magnet or wire, or laserbeacon techniques fill in gaps in GPS position information. Integratedphysical limit-, infrared-, radar-, and/or ultrasonic-based sensorsprovide for personnel detection around said autonomous machines for safemachine operation.

LIST OF ACRONYMS

CAIDOC—containerized plant assembly input/disassembly output conveyor(part of PAU)CGAA—container gripping adapter assembly (part of PAUCGU—container gripping unit (part of PAU)CLAA—container lifting adapter assembly (part of PAUCLU—container lifting unit (part of PAU)CPC—containerized plant conveyorCPSC—containerized plant spacing conveyorCSC—containerized plant spacing conveyorFMSRT—feature mapping system, remote, trailer-mountedFMUH—feature mapping unit, hand-heldGPS—global positioning systemHMI—human-machine interfacePA—pallet assemblyPC—pallet (/grid/pallet assembly/pallet stack/grid stack) conveyorPACTU—pallet assembly central transfer unitPAFTU—pallet assembly field transfer unitPAGTU—pallet assembly greenhouse transfer unitPAIDOC—pallet assembly input/disassembly output conveyor (part of PAU)PAODIC—pallet assembly output/disassembly input conveyor (part of PAU)PAS—pallet assembly/disassembly systemPATT—pallet assembly transport trainPAU—pallet assembly/disassembly unitPE—pallet stack elevator (part of PGSA)PGRU—pallet & grid rotating unitPGSA—pallet & grid stack accumulatorPGSC—pallet & grid stack conveyorPGSU—pallet & grid stacking/unstacking unitPGWU—pallet & grid washing unitPET—polyethylene terephthalatePXC—pallet crossover conveyorRTK GPS—real-time kinematic global positioning systemSCADA—supervisory control and data acquisition

DESCRIPTION OF THE DRAWINGS

Referring to the drawings which form part of this disclosure:

FIG. 1 is a basic illustration of a nursery automation system inaccordance with a first embodiment of the invention.

FIG. 2A is a perspective view of a first embodiment of aspaced-container (no. 1/trade gallon) pallet assembly in accordance withthe invention.

FIG. 2B is a perspective exploded view of the pallet assembly of FIG.2A, viewed from below the assembly.

FIG. 2C is a perspective exploded close-up view of one segment of thepallet assembly of FIG. 2A, viewed from above the assembly.

FIG. 2D is a perspective exploded close-up view of the segment of thepallet assembly of FIG. 2A, viewed from below the assembly.

FIG. 2E is a partial elevation section view of the lower left-handportion of a segment of the pallet assembly of FIG. 2A, looking indirection 2E-2E of FIG. 2A, showing a pallet configuration having awater reservoir, wherein the free surface of the reservoir water isbelow the bottom of the installed container.

FIG. 2F is a partial elevation section view of the lower left-handportion of a segment of the pallet assembly of FIG. 2A, looking indirection 2F-2F of FIG. 2A, showing a pallet configuration having awater reservoir, wherein the free surface of the reservoir water isbelow the bottom of the installed container.

FIG. 2G is a partial elevation section view of the lower left-handportion of a segment of the pallet assembly of FIG. 2A, looking indirection 2E-2E of FIG. 2A, showing a pallet configuration having awater reservoir, wherein the free surface of the reservoir water isabove the bottom of the installed container, resulting in wicking of aportion of reservoir water into container soil.

FIG. 2H is a partial elevation section view of the lower left-handportion of a segment of the pallet assembly of FIG. 2A, looking indirection 2F-2F of FIG. 2A, showing a pallet configuration having awater reservoir, wherein the free surface of the reservoir water isabove the bottom of the installed container, resulting in wicking of aportion of reservoir water into container soil.

FIG. 3A is a perspective view of a second embodiment of aspaced-container (no. 1/trade gallon) pallet assembly in accordance withthe invention.

FIG. 3B is a perspective exploded view of a split elevation section ofone-quarter of one receptacle of a pallet assembly in accordance with afirst embodiment of the invention, said split section occurring at twoperpendicular vertical planes intersecting one another along verticalcenterline of the pallet assembly receptacle.

FIG. 3C is the same as FIG. 3, except with pallet assembly componentsnot exploded.

FIG. 3D is a partial elevation section view of the lower left-handportion of a segment of the pallet assembly of FIG. 3A, looking indirection 3D-3D of FIG. 3A, showing a pallet configuration having twointegral water reservoirs, wherein the free surface of the highestreservoir water is below the bottom of the installed container.

FIG. 3E is a partial elevation section view of the lower left-handportion of a segment of the pallet assembly of FIG. 3A, looking indirection 3E-3E of FIG. 3A, showing a pallet configuration having twointegral water reservoirs, wherein the free surface of the highestreservoir water is below the bottom of the installed container.

FIG. 3F is a partial elevation section view of the lower left-handportion of a segment of the pallet assembly of FIG. 3A, looking indirection 3D-3D of FIG. 3A, showing a pallet configuration having twointegral water reservoirs, wherein the free surface of the highestreservoir water is above the bottom of the installed container,resulting in wicking of a portion of reservoir water into containersoil.

FIG. 3G is a partial elevation section view of the lower left-handportion of a segment of the pallet assembly of FIG. 3A, looking indirection 3E-3E of FIG. 3A, showing a pallet configuration having twointegral water reservoirs, wherein the free surface of the highestreservoir water is above the bottom of the installed container,resulting in wicking of a portion of reservoir water into containersoil.

FIG. 4 is a detailed elevation section view of a first embodiment of thecontainer lip engaging a corresponding pallet receptacle recess.

FIG. 5 is a perspective exploded view of a first embodiment of acontiguous container (no. 1/trade gallon) pallet assembly in accordancewith the invention.

FIG. 6 is a perspective exploded view of a first embodiment of acontiguous tray (10″×20″ nominal) pallet assembly in accordance with theinvention.

FIG. 7 is a perspective view of a split elevation section of one-quarterof a container with a first embodiment of a container liftingstabilization feature comprising an annular groove in container bottomwall and drain holes through container bottom wall, optionally strictlyon container center side of said groove, said split section occurring attwo perpendicular vertical planes intersecting one another alongvertical centerline of container.

FIG. 8 is a perspective view of a split elevation section of one-quarterof a container with a first embodiment of a container liftingstabilization feature comprising an annular groove in container bottomwall and drain holes through container bottom wall, optionally strictlyoutside of said groove, said split section occurring at twoperpendicular vertical planes intersecting one another along verticalcenterline of container.

FIG. 9 is a perspective view of a split elevation section of one-quarterof a container with a first embodiment of a container liftingstabilization feature comprising an annular groove in container bottomwall and drain holes optionally strictly through container side wall,proximal to container bottom, said split section occurring at twoperpendicular vertical planes intersecting one another at the verticalcenterline of container.

FIG. 10 is a perspective view of one container receptacle of a spacedcontainer pallet, with a second embodiment of a collected water overflowdrainage system, comprising a circular array of equally spaced,vertically punched holes through the upper wall of a foliage-deflectingupward protrusion from receptacle funnel wall, with proximal waterdiverter immediately up slope from each hole.

FIG. 11 is a perspective view of one container receptacle of a spacedcontainer pallet, with a third embodiment of a collected water overflowdrainage system, comprising a circular array of equally spaced,vertically punched holes each through the lower, sloped end wall of awater diverter, each said hole immediately up slope from a foliagediverting upward protrusion.

FIG. 12 is a perspective view of one container receptacle of a spacedcontainer pallet, with a fourth embodiment of a collected water overflowdrainage system, comprising a circular array of equally spaced,vertically punched holes through receptacle funnel wall, with proximalwater diverter immediately up slope from each hole.

FIG. 13 is a perspective view of one container receptacle of a spacedcontainer pallet, with a fifth embodiment of a collected water overflowdrainage system, comprising a circular array of equally spaced,vertically punched holes, a pair of each through sloped side walls of acorresponding water diverter.

FIG. 14 is a perspective view of one container receptacle of a spacedcontainer pallet, with a sixth embodiment of a collected water overflowdrainage system, comprising a circular array of equally spaced, radiallypunched holes each through the lower, sloped end wall of a waterdiverter.

FIG. 15 is a perspective view of one container receptacle of a spacedcontainer pallet, with a seventh embodiment of a collected wateroverflow drainage system, comprising a circular array of equally spaced,radially punched holes each through the upper, substantially verticalend wall of a water radial drain trough.

FIG. 16 is a perspective view of a split elevation section ofone-quarter of a container receptacle/funnel of a spaced containerpallet, with a second embodiment of a container receptacle comprising acontainer lip sealing area and ribbed, substantially open sides.

FIG. 17 is a normal view of an elevation section of one-quarter of acontainer receptacle/funnel of a spaced container pallet, with a thirdembodiment of a container receptacle/container seal arrangementcomprising a relatively shallow receptacle with a stepped container sidewall for sealing with receptacle, and container water inlet holesthrough container side wall, immediately above container side wall step.

FIG. 18 is a normal view of an elevation section of one-quarter of acontainer receptacle/funnel of a spaced container pallet, with a fourthembodiment of a container receptacle/container seal arrangementcomprising a relatively shallow receptacle with sealing occurring atbottom, outer perimeter of container and container water inlet holesthrough container side wall, immediately above container bottom wall.

FIG. 19 is a normal view of an elevation section of a second embodimentof a sealing arrangement between a container and a receptacle/funnel ofa spaced container pallet.

FIG. 20 is a normal view of an elevation section of a third embodimentof a sealing arrangement between a container and a receptacle/funnel ofa spaced container pallet.

FIG. 21 is a normal view of an elevation section of a fourth embodimentof a sealing arrangement between a container and a receptacle/funnel ofa spaced container pallet.

FIG. 22 is a normal view of an elevation section of a fifth embodimentof a sealing arrangement between a container and a receptacle/funnel ofa spaced container pallet.

FIG. 23 is a normal view of an elevation section of a sixth embodimentof a sealing arrangement between a container and a receptacle/funnel ofa spaced container pallet.

FIG. 24 is a normal view of an elevation section of a seventh embodimentof a sealing arrangement between a container and a receptacle/funnel ofa spaced container pallet.

FIG. 25 is a perspective view of a split elevation section ofone-quarter of one segment of a first embodiment of a chute arrangementfor conveying collected applications from pallet into container upperend, in accordance with the invention, comprising an array of genericapplication conveying chutes, said split section occurring at twoperpendicular vertical planes intersecting one another along verticalcenterline of the pallet container receptacle.

FIG. 26 is a close-up plan view of a portion of the chute arrangement ofFIG. 27, less containerized plant canopy, showing in part the spatialrelationship between a mounted container and two adjoining, integralflexible chutes of a plurality of such chutes spaced along the perimeterof the associated container receptacle hole through the upper wallportion of the pallet.

FIG. 27 is a section view of a portion of the pallet-containerapplication conveying chute arrangement of FIG. 26, looking in direction27-27 of FIG. 26, said view rotated clockwise 105 degrees from FIG. 26section 27-27 projection, showing spatial relationship between chute andlip of a container installed in associated container receptacle.

FIG. 28 is substantially the same as FIG. 27, showing chute deflectingdownward under interaction with lip of container being installed intoassociated container receptacle of said pallet.

FIG. 29 is substantially the same as FIG. 27, showing chute deflectingoutward and upward under interaction with lip of container being removedfrom associated container receptacle of said pallet.

FIG. 30 is a close-up plan view of a portion of a second embodiment of apallet-container application conveying means, less containerized plantcanopy, showing in part the spatial relationship between a mountedcontainer and two adjoining, integral spring hinged chutes of aplurality of such chutes spaced along the perimeter of the associatedcontainer receptacle hole through the upper wall portion of the pallet.

FIG. 31 is a section view of a portion of the pallet-containerapplication conveying chute arrangement of FIG. 30, looking in direction31-31 of FIG. 30, said view rotated clockwise 90 degrees from FIG. 30section 31-31 projection, showing spatial relationship between chute andlip of a container installed in associated container receptacle.

FIG. 32 is substantially the same as FIG. 31, except with containerremoved, showing free, molded and trimmed state of chute.

FIG. 33 is substantially the same as FIG. 31, except with containerbeing installed, showing downward and outward deflection of chuteresulting from contact between container lip and chute.

FIG. 34 is substantially the same as FIG. 31, except with containerbeing removed, showing upward and outward deflection of chute resultingfrom contact between container lip and chute.

FIG. 35 is a close-up plan view of a portion of a third embodiment of apallet-container application conveying chute arrangement, lesscontainerized plant canopy, showing in part the spatial relationshipbetween a mounted container and two adjoining, integral spring hingedchutes of a plurality of such chutes spaced along the perimeter of theassociated container receptacle hole through the upper wall portion ofthe pallet.

FIG. 36 is a partial panoramic elevation view of a portion of thepallet-container application conveying chute arrangement of FIG. 35,looking in direction 36-36 of FIG. 35, showing spatial relationshipbetween chute and lip of installed container.

FIG. 37 is the same as FIG. 36, except with container removed, showingfree, molded and trimmed state of chute.

FIG. 38 is a section view of a portion of the pallet-containerapplication conveying chute arrangement of FIG. 35, looking in direction38-38 of FIG. 35, said view rotated clockwise 105 degrees from FIG. 35section 38-38 projection, showing spatial relationship between chute andlip of a container installed in associated container receptacle.

FIG. 39 is the same as FIG. 38, except with container removed, showingfree, molded and trimmed state of chute.

FIG. 40 is a partial panoramic elevation view of a portion of a fourthembodiment of a pallet-container application conveying chutearrangement, looking in direction comparable to 36-36 of FIG. 35,showing spatial relationship between chute and lip of installedcontainer.

FIG. 41 is the same as FIG. 40, except with container removed, showingfree, molded and trimmed state of chute

FIG. 42 is a section view of a portion of the pallet-containerapplication conveying chute arrangement of FIG. 40, looking in direction42-42 of FIG. 40, showing free, molded and trimmed state of chute.

FIG. 43 is the same as FIG. 42, showing spatial relationship betweenchute and lip of a container installed in associated containerreceptacle.

FIG. 44 is a section view of a portion of a fifth embodiment of apallet-container application conveying chute arrangement, looking indirection comparable to 2-42 of FIG. 40, showing spatial relationshipbetween chute and lip of a container installed in associated containerreceptacle.

FIG. 45 is the same as FIG. 44, except with container being installed,showing chute downward and outward deflection on interaction withcontainer lip.

FIG. 46 is the same as FIG. 44, except with container being removed,showing chute upward and outward deflection on interaction withcontainer lip.

FIG. 47 is a perspective, exploded view of another embodiment of aspaced container (no. 1/trade gallon) pallet assembly, incorporating apallet having funnels with square outer perimeters, which mayincorporate have seal- or chute-based (shown) water conveyance frompallet upper wall into mounted containers.

FIG. 48 is a perspective, exploded view of another embodiment of acontiguous container (no. 1/trade gallon) pallet assembly, incorporatinga pallet of low height relative to container and having circular arraysof relatively slender upward protrusions forming sides of containerreceptacles.

Machinery PAS

FIG. 49 is a plan view of a first embodiment of a palletassembly/disassembly system with an autonomously guided a palletassembly transport train.

FIG. 50 is a first side elevation view of the system of FIG. 49, lookingin direction 50-50 of FIG. 49.

FIG. 51 is a second side elevation view of the system of FIG. 49,looking in direction 51-51 of FIG. 49.

FIG. 52 is a third side elevation view of the system of FIG. 49, lookingin direction 52-52 of FIG. 49.

FIG. 53 is a fourth side elevation view of the system of FIG. 49,looking in direction 53-53 of FIG. 49.

FIG. 54 is a perspective overhead view of the system of FIG. 49.

PATT

FIG. 55 is a perspective view of an autonomously-guided pallet assemblytransport train of a first embodiment, comprising a multi-deck driveunit and two multi-deck trailers.

FIG. 56 is a perspective view of the underside of the pallet assemblytransport train of FIG. 55.

PACTU

FIG. 57 is an overhead perspective view of a pallet assembly centraltransfer unit forming part of the pallet assembly/disassembly system ofFIG. 49, configured to transfer pallet assemblies between palletassembly transport train and an adjoining system conveyor.

FIG. 58A is a close-up overhead perspective view of the fork and forkelevator portion of a pallet assembly central transfer unit forming partof the pallet assembly/disassembly system of FIG. 49.

FIG. 58B is an overhead perspective view of a pallet assembly centraltransfer unit forming part of the pallet assembly/disassembly system ofFIG. 49, preparing to transfer pallet assemblies to pallet assemblytransport train from an adjoining system conveyor.

FIG. 58C is an overhead perspective view of a pallet assembly centraltransfer unit forming part of the pallet assembly/disassembly system ofFIG. 49, engaging a pair of pallet assemblies in process of transferringsuch pallet assemblies to pallet assembly transport train from anadjoining system conveyor.

FIG. 58D is an overhead perspective view of a pallet assembly centraltransfer unit forming part of the pallet assembly/disassembly system ofFIG. 49, having lifted a pair of pallet assemblies to elevation ofuppermost deck of pallet assembly transport train in process oftransferring such pallet assemblies to pallet assembly transport trainfrom an adjoining system conveyor.

FIG. 58E is an overhead perspective view of a pallet assembly centraltransfer unit forming part of the pallet assembly/disassembly system ofFIG. 49, placing a pair of pallet assemblies onto uppermost deck ofpallet assembly transport train in process of transferring such palletassemblies to pallet assembly transport train from an adjoining systemconveyor.

FIG. 58F is an overhead perspective view of a pallet assembly centraltransfer unit forming part of the pallet assembly/disassembly system ofFIG. 49, having retracted from having placed a pair of pallet assembliesonto uppermost deck of pallet assembly transport train, preparing toreturn to the position represented in FIG. 57, in process oftransferring such pallet assemblies to pallet assembly transport trainfrom an adjoining system conveyor.

PAU

FIG. 59A is a first perspective side view of a palletassembly/disassembly unit (PAU) and integral conveyors forming part ofthe pallet assembly/disassembly system of FIG. 49.

FIG. 59B is a perspective frontal view of the PAU of FIG. 59A, with thepallet assembly outfeed/pallet disassembly infeed conveyor removed,providing an improved view of the container lifting unit.

FIG. 59C is a second perspective side view of a vertical section of thePAU of FIG. 59A, looking upward, wherein section is taken immediatelyinboard of the end of the container lifting unit portion of the PAU.

FIG. 59D is a side upward-looking perspective view of a vertical sectionof the container lifting unit portion of the PAU of FIG. 59A, whereinsection is 60 degrees from associated pallet conveyor flow directions.

FIG. 59E is the same as FIG. 59D, except also showing PAU interactionwith a pallet and containerized plants.

FIG. 59F is a downward-looking perspective view of a vertical section ofone of a plurality of conveyor segments forming container lifting unitconveyor portion of PAU of FIG. 59A, wherein section is tangent topallet conveyor flow directions.

FIG. 59G is a plan view of PAU of FIG. 59A, with container lifting andgripping attachments removed from their operating mounts and seated intheir storage fixture on adjoining conveyor.

FIG. 59H is a side perspective view of PAU of FIG. 59A, arranged asdescribed in FIG. 59G.

FIG. 59I is an overhead perspective view of container lifting andgripping attachments of PAU of FIG. 59A, exploded to show interactionfor storage preparation.

FIG. 59J is an overhead perspective view of the PAU of FIG. 59A, showinginitial interaction with the first row of pallet assembly containerreceptacles and containers, wherein container-lifting rods of containerlifting unit have advanced upward into contact with associatedcontainers.

FIG. 59K is an overhead perspective view of the PAU of FIG. 59A, showinglowering and lateral shuttling of container grippers to suitableelevation for interaction with containers to be lifted, generallysimultaneously with upward advancement of container lifting rods ofcontainer lifting unit for engagement with a first row of palletassembly container receptacles and containers.

FIG. 59L is an overhead perspective view of the PAU of FIG. 59A, showinginteraction with the first row of pallet assembly container receptaclesand containers, wherein container grippers are positioned to engagecontainers lifted by upwardly advanced lifting rods of container liftingunit.

FIG. 59M is an overhead perspective view of the PAU of FIG. 59A, showinginteraction with the first row of pallet assembly container receptaclesand containers, wherein container grippers have captured containerslifted by upwardly advanced lifting rods of container lifting unit.

FIG. 59N is an overhead perspective view of the PAU of FIG. 59A, showinginteraction with the first row of pallet assembly container receptaclesand containers, wherein container grippers have raised capturedcontainers to an elevation suitable for horizontal translation tocontainer conveyor.

FIG. 59P is an overhead perspective view of the PAU of FIG. 59A, showingindexing by pallet conveyors of pallet assemblies in process,positioning second row of containers for lifting, while containergrippers generally simultaneously place captured containers ontocontainer conveyor.

FIG. 59Q is an overhead perspective view of the PAU of FIG. 59A, showinglateral indexing of container lifting rods while container grippersgenerally simultaneously become disengaged with containers placed ontocontainer conveyor.

FIG. 59R is an overhead perspective view of the PAU of FIG. 59A, showingretraction of container grippers, allowing containers placed oncontainer conveyor to be conveyed away.

PGWU

FIG. 60A is a plan view of a pallet- and grid-washing unit and a palletand grid rotator unit at each end of pallet and grid washing unit, inaccordance with a first embodiment of the invention.

FIG. 60B is a first elevation view of pallet and grid washing unit ofFIG. 60A, looking in direction 60B-60B of FIG. 60A, shown with palletrotator units removed, and with pallet and grid washing system androtator units in standard operating mode.

FIG. 60C is the same as FIG. 60B, except shown with pallet rotator unitsin place, and with pallet and grid washing system and rotator units inbypass mode.

FIG. 60D is a second elevation view of pallet and grid washing unit ofFIG. 60A, looking in direction 60D-60D of FIG. 60A, shown with palletand grid washing system and rotator units in standard operating mode.

FIG. 60E is an overhead perspective view of pallet and grid washing unitof FIG. 60A, shown with pallet and grid washing system and rotator unitsin standard operating mode.

FIG. 60F is a side perspective view of left-hand (where pallet and gridflow direction is forward), vertical plane, horizontal flow pallet andgrid conveyor of pallet and grid washing unit of FIG. 60A, showingrinse/wash water jet arrays and an air drying jet array.

PGRU

FIG. 60G is a plan view of a pallet and grid rotator unit in accordancewith a first embodiment of the invention.

FIG. 60H is a side elevation view of a pallet and grid rotator unit ofFIG. 60G, looking in direction 60H-60H of FIG. 60G.

FIG. 60I is a front elevation view of a pallet and grid rotator unit ofFIG. 60G, looking in direction 60I-60I of FIG. 60G.

FIG. 60J is an overhead perspective view of a pallet and grid rotatorunit of FIG. 60G.

FIG. 60K is a front elevation view of the pallet and grid rotator unitof FIG. 60G, shown in the state for transitioning of two pallets nestedin two grids to or from an adjoining pallet conveyor external to palletand grid washing unit, and holding two pallets nested in two grids.

FIG. 60L is the same as FIG. 60K, except with edge conveyors advancedinto contact with held pallet edges.

FIG. 60M is a front elevation view of the pallet and grid rotator unitof FIG. 60G, shown rotated up (to ‘pallets on edge’ state), and holdingtwo pallets nested in two grids.

FIG. 60N is the same as FIG. 60M, except with edge conveyors retracted,placing supported edges of held pallets at elevation of pallet and gridwashing unit main conveyor, suitable for transitioning.

PGSU

FIG. 61A is an overhead perspective view of a pallet/gridstacking/destacking unit and integral conveyors forming part of thepallet assembly/disassembly system of FIG. 49.

FIG. 61B is an overhead perspective view of one pallet gripper headassembly forming part of the pallet stacking/destacking unit of FIG.61A.

FIG. 61C is an underneath perspective, partially exploded, view of thepallet gripper head assembly of FIG. 61B.

FIG. 61D depicts two side-by-side pairs of elevation section segments ofa portion of pallet/grid stacking unit of FIG. 61A showing the spatialinteraction between pallet hooks and pallets at start of a de-stackingcycle.

FIG. 61E depicts two side-by-side pairs of elevation section segments ofa portion of pallet/grid stacking unit of FIG. 61A showing the spatialinteraction between pallet hooks and pallets with singulation hook pairhaving spaced bottommost pallet downward from a hook-borne partialpallet stack to ensure reliable release in a de-stacking cycle.

FIG. 61F depicts two side-by-side pairs of elevation section segments ofa portion of pallet/grid stacking unit of FIG. 61A showing the spatialinteraction between pallet hooks and pallets with a downwardly spacedpallet released and removed from a hook-borne partial pallet stack in ade-stacking cycle.

FIG. 61G depicts two side-by-side pairs of elevation section segments ofa portion of pallet/grid stacking unit of FIG. 61A showing the spatialinteraction between pallet hooks and pallets with pallet-singulatinghook pair having moved upward ready to engage new bottommost pallet ofhook-borne partial pallet stack in a de-stacking cycle.

FIG. 61H depicts two side-by-side pairs of elevation section segments ofa portion of pallet/grid stacking unit of FIG. 61A showing the spatialinteraction between pallet hooks and pallets with pallet-singulatinghook pair engaging new bottommost pallet of hook-borne partial palletstack in a de-stacking cycle.

FIG. 61I depicts two side-by-side pairs of elevation section segments ofa portion of pallet/grid stacking unit of FIG. 61A showing the spatialinteraction between pallet hooks and pallets with pallet holding hookpair disengaged from new bottommost pallet of hook-borne partial palletstack in a de-stacking cycle.

FIG. 61J depicts two side-by-side pairs of elevation section segments ofa portion of pallet/grid stacking unit of FIG. 61A showing the spatialinteraction between pallet hooks and pallets with pallet singulationhook pair having returned downward to its original position, havinglowered remaining partial pallet stack with it in a de-stacking cycle.

FIG. 61K depicts two side-by-side pairs of elevation section segments ofa portion of pallet/grid stacking unit of FIG. 61A showing the spatialinteraction between pallet hooks and pallets with pallet holding hookpair having engaged second bottommost pallet of remaining hook-bornepartial pallet stack in a de-stacking cycle.

FIG. 61L is an overhead perspective view of the pallet/gridstacking/destacking unit of FIG. 61A, starting a stacking process.

FIG. 61M is an overhead perspective view of the pallet/gridstacking/destacking unit of FIG. 61A, in a second step of a stackingprocess, engaging a first pallet on a first side of an associated palletconveyor.

FIG. 61N is an overhead perspective view of the pallet/gridstacking/destacking unit of FIG. 61A, in a third step of a stackingprocess, having engaged and separated a first pallet from an associatedfirst grid on a first side of an associated pallet conveyor.

FIG. 61P is an overhead perspective view of the pallet/gridstacking/destacking unit of FIG. 61A, in a fourth step of a stackingprocess, wherein pallet/grid gripper heads have shuttled to above asecond side an associated pallet conveyor.

FIG. 61Q is an overhead perspective view of the pallet/gridstacking/destacking unit of FIG. 61A, in a fifth step of a stackingprocess, engaging a second pallet on a second side of an associatedpallet conveyor.

FIG. 61R is an overhead perspective view of the pallet/gridstacking/destacking unit of FIG. 61A, in a sixth step of a stackingprocess, having engaged and separated a second pallet from an associatedsecond grid on a second side of an associated pallet conveyor.

FIG. 61S is an overhead perspective view of the pallet/gridstacking/destacking unit of FIG. 61A, in a seventh step of a stackingprocess, wherein pallet conveyor has indexed associated pallets andgrids for a subsequent, similar stacking sequence.

PAGTU

FIG. 62A is a plan view of a pallet assembly greenhouse transfer unit inaccordance with a first embodiment of the invention.

FIG. 62B is a front elevation view of a pallet assembly greenhousetransfer unit in accordance with a first embodiment of the invention.

FIG. 62C is a rear elevation view of a pallet assembly greenhousetransfer unit in accordance with a first embodiment of the invention.

FIG. 62D is a side elevation view of a pallet assembly greenhousetransfer unit in accordance with a first embodiment of the invention.

FIG. 62E is a perspective view of a pallet assembly greenhouse transferunit in accordance with a first embodiment of the invention.

FIG. 62F is a section view of the fork vertical guide (mast)/driveportion of a pallet assembly greenhouse transfer unit in accordance witha first embodiment of the invention, looking in direction 62F-62F ofFIG. 62B.

FIG. 62G is a perspective view of a pallet assembly greenhouse transferunit in accordance with a first embodiment of the invention, with itsfork elevated above the tops of canopies of palletized containerizedplant material adjoining that to be retrieved.

FIG. 62H is a perspective view of the pallet assembly greenhousetransfer unit of FIGS. 62A-62F following fork rotation above adjoiningplant material canopies, preparing for lateral engagement with aproximal pallet assembly.

FIG. 62I is a perspective view of the pallet assembly greenhousetransfer unit of FIGS. 62A-62F with its fork aligned and at an elevationfor lateral engagement with a proximal pallet assembly.

FIG. 62J is a perspective view of the pallet assembly greenhousetransfer unit of FIGS. 62A-62F having its fork engaged with a palletassembly perpendicular to the line of travel of the pallet assemblygreenhouse transfer unit primary drive wheels.

FIG. 62K is a perspective view of the pallet assembly greenhousetransfer unit of FIGS. 62A-62F turning toward fork-engaged palletassembly, establishing a stable attitude for lifting fork-engaged palletassembly.

FIG. 62L is a perspective view of the pallet assembly greenhousetransfer unit of FIGS. 62A-62F lifting fork-engaged pallet assemblysufficient to clear adjoining plant material.

FIG. 62M is a perspective view of the pallet assembly greenhousetransfer unit of FIGS. 62A-62F retracting load to lift mast, maximizingstability for pallet assembly greenhouse transfer unit travel.

FIG. 62N is a perspective view of the pallet assembly greenhousetransfer unit of FIGS. 62A-62F beginning travel to delivery point.

FIG. 62P is a plan view of the pallet assembly greenhouse transfer unitof FIGS. 62A-62F engaging a pallet assembly on the top deck of a palletassembly transfer train.

FIG. 62Q is a first elevation view of the pallet assembly greenhousetransfer unit of FIGS. 62A-62F engaging a pallet assembly on the topdeck of a pallet assembly transfer train.

FIG. 62R is a second elevation view of the pallet assembly greenhousetransfer unit of FIGS. 62A-62F engaging a pallet assembly on the topdeck of a pallet assembly transfer train.

FIG. 62S is a perspective view of the pallet assembly greenhousetransfer unit of FIGS. 62A-62F engaging a pallet assembly on the topdeck of a pallet assembly transfer train.

FIG. 62T is a perspective view of a fork assembly for a the palletassembly greenhouse transfer unit of FIGS. 62A-62F, in accordance with afirst embodiment of the invention.

FIG. 62U is a perspective view of a section of the fork assembly of FIG.62T, wherein section is taken at a vertical plane centered on a forktine depicted in FIG. 62T.

PAFTU

FIG. 63A is a perspective view of a pallet assembly field transfer unitof a first embodiment.

FIG. 63B is a perspective close-up view of the pallet assembly handlinghead of the pallet assembly field transfer unit of FIG. 63A.

FIG. 63C is a perspective view of a first embodiment of the palletassembly field transfer unit of FIG. 63A, engaging a pallet assemblytransport train.

FIG. 63D is a perspective view of the pallet assembly field transferunit of FIG. 63A, holding a pallet assembly just retrieved from or aboutto be placed in a nursery bed to side of said pallet assembly fieldtransfer unit.

FIG. 63E is a perspective view of the pallet assembly field transferunit of FIG. 63A, engaging a pallet assembly situated in a nursery bedto side of said pallet assembly field transfer unit.

FIG. 63F is a perspective view of the pallet assembly field transferunit of FIG. 63A, engaging a pallet assembly situated in a nursery bedbeneath said pallet assembly field transfer unit.

FIG. 63G is a perspective view of the pallet assembly field transferunit of FIG. 63A, holding a pallet assembly just retrieved from or aboutto be placed in a nursery bed beneath said pallet assembly fieldtransfer unit.

FIG. 63H is a plan view of the unit of FIG. 63A configured to operate innarrow aisles between beds, such aisles running parallel to driveway inwhich pallet assembly transport train operates.

FIG. 63I is a plan view of the unit of FIG. 63A configured to operate onnarrow beds running perpendicular to driveway in which pallet assemblytransport train operates.

FMUH

FIG. 64A is a perspective view of one configuration of a hand-heldnursery feature-mapping device, in accordance with a first embodiment ofthe container gripping mechanisms of the invention.

FIG. 64B is a perspective view of the hand-held nursery feature-mappingdevice of FIG. 64A, shown momentarily mounted on an irrigation sprinklerhead.

FIG. 64C is a perspective view of the hand-held nursery feature-mappingdevice, shown configured with an attachable probe attached.

FIG. 64D is a perspective view of an operator utilizing the hand-heldnursery feature-mapping device of FIG. 64C, in accordance with a firstembodiment of the invention.

FMSRT

FIG. 65A is a perspective view of a nursery remote feature-mappingtrailer in accordance with a first embodiment of the invention

FIG. 65B is a perspective illustration of the spatial relationship andmovements of two remote nursery feature-mapping trailers each beingtowed by a 4-wheeled vehicle in accordance with a first embodiment ofthe invention

PAS Emb2

FIG. 66 is a perspective overhead view of a second embodiment of apallet assembly/disassembly system with an autonomously guided a palletassembly transport train, configured for assembly and disassembly ofpallet assemblies.

FIG. 67 is a perspective overhead view of a second embodiment of apallet assembly/disassembly system with an autonomously guided a palletassembly transport train, configured for unit processing of completepallet assemblies.

PGSU Emb2

FIG. 68 is an overhead perspective view of a pallet/gridstacking/destacking unit and integral conveyors forming part of thepallet assembly/disassembly system of FIG. 66.

FIG. 69 is a second overhead perspective view of a pallet/gridstacking/destacking unit and integral conveyors forming part of thepallet assembly/disassembly system of FIG. 66.

PAU CGU Emb1

FIG. 70 is a plan view of a container active gripper assembly portion ofa pallet assembly/disassembly system of FIG. 49, in accordance with afirst embodiment of the invention.

FIG. 71 is a side elevation view of the container active gripperassembly of FIG. 70, looking in direction 71-71 of FIG. 70.

FIG. 72A is a frontal elevation view of the container active gripperassembly of FIG. 70, looking in direction 72A-72A of FIG. 70.

FIG. 72B is a first overhead perspective view of the container activegripper assembly of FIG. 70.

FIG. 72C is a second overhead perspective view of the container activegripper assembly of FIG. 70, viewed from side of vertical riser membersopposite container gripper tines.

PAU CGU Emb2

FIG. 73A is a plan view of a container active gripper assembly portionof a pallet assembly/disassembly system of FIG. 49, in accordance with asecond embodiment of the container gripping mechanisms of the invention.

FIG. 73B is a close-up plan view of one pincer of FIG. 73A.

FIG. 73C is a frontal elevation view of the container active gripperassembly of FIG. 73A, looking in direction 73C-73C of FIG. 73A.

FIG. 73D is a side perspective view of a vertical section of thecontainer active gripper assembly of FIG. 73A, wherein section bisectsthe base of a gripper tine.

PAGTU Emb2

FIG. 74A is an overhead perspective view of a pallet assembly greenhousetransfer unit of a second embodiment, having a fork—shown down andretracted—, which is mounted on a knuckle boom, which is, in turn,mounted on a crawler track carriage having a turntable.

FIG. 74B is an overhead perspective view of the pallet assemblygreenhouse transfer unit of FIG. 74A, with its fork down and extended.

FIG. 74C is an overhead perspective view of the pallet assemblygreenhouse transfer unit of FIG. 74A, with its fork partially elevatedand extended.

FIG. 74D is an overhead perspective view of the pallet assemblygreenhouse transfer unit of FIG. 74A, with its fork elevated andretracted.

FIG. 74E is an overhead perspective view of the pallet assemblygreenhouse transfer unit of FIG. 74A, with its fork elevated andextended.

FIG. 74F is an underneath perspective view of the pallet assemblygreenhouse transfer unit of FIG. 74A, with its fork partially elevatedand retracted and the body swiveled about the unit track carriage.

PAGTU Emb3

FIG. 75 is an underneath perspective view of a pallet assemblygreenhouse transfer unit of a third embodiment, having a fork—shownpartially elevated and retracted—, which is mounted on a knuckle boom,which is, in turn, mounted on a four-wheel, rubber-tire carriage havinga turntable.

PAFTU Emb2

FIG. 76 is a perspective view of a pallet assembly field transfer unitof a second embodiment.

DESCRIPTION OF THE INVENTION General Arrangement

Referring now to the illustration of FIG. 1, a general layout of asystem in accordance with a first embodiment of the invention is shown.The first embodiment of the invention comprises an automated system 100for handling and performing various processes on containerized nurserystock 110 in a large horticultural nursery, wherein a significantportion of the containerized nursery stock 110 spends a significantportion of growing time outdoors or in greenhouses. Key components of afirst embodiment of the invention include: multiple configurations ofcontainerized plant material pallet assemblies—contiguous tray arraypallet assembly 300, contiguous containerized plant array palletassembly 400 and spaced containerized plant array pallet assembly 500—,shown in FIGS. 2 through 48, including innovative features of componentsincorporated in pallet assemblies 300, 400 and 500; GPS satellites 114and associated radio signals 115; a base station 112, establishing anRTK GPS reference position and associated radio signals 120, andproviding system master control and associated fixed 118 and radio 122links with stationary and autonomously guided mobile machinery; anautonomously guided pallet assembly field transfer unit 1100; anautonomously guided pallet assembly transport train 1200; anautonomously guided pallet assembly greenhouse transfer unit 1300; and acentral pallet assembly/transfer system 1400. Machinery is shown inFIGS. 49-63 and 66-76. Invention also includes tools to facilitatenursery mapping/surveying, shown in FIGS. 64 and 65.

Pallet Assemblies FIGS. 2A, 2B—Pallet Assembly: Pallet Spaced Hex W/Grid

Invention comprises in part a family of containerized plant palletassemblies, a first embodiment of which comprises a spaced containerpallet assembly 500 like that shown in FIGS. 2A through 2H. Completepallet assemblies are shown in FIGS. 2A and 2B. Pallet assembly 500incorporates a thin-wall pallet 502 that unitizes in a planar arraymultiple individual containerized plants 200. Pallet assembly 500 mayfurther incorporate an optional pallet-stiffening grid 800 into whichpallet 502 nests.

Pallet 502 comprises an array of mutually contiguous, coupled shallowfunnel-shaped segments in which are centered openings from which extendhollow downward protrusions forming container receptacles 509 whichcomplement shapes of containers to be received. Unitization ofindividual containerized plants into pallet assemblies 500 substantiallyreduces the ratio of the effective unit height/least plan area dimensioncompared with free-standing individual containerized plants 200 and,thus, provides for a corresponding substantial gain in stability ofposition and orientation of incorporated containerized plants 200relative to freestanding individual containerized plants 200. Suchstabilization increase substantially averts toppling of incorporatedcontainerized plants 200 subjected to wind that would readily topplefreestanding containerized plants 200. Stability increase also appliesin transportation of incorporated containerized plants 200. Manipulationof individual containerized plants 200 is conducted solely by a centralpallet assembly/disassembly system 1400, described below, in which closecontrol over movement of such plant material to ensures highly reliablesystem operation.

Outer perimeter of pallet upper wall 504 incorporates a stiffening lip564, which allows pallets to abut one another without overlapping ofupper walls 504 of adjoining pallets. Such abutment promotes substantialsealing of air gaps otherwise existing between pallets, providing—withsupplemental barriers—a significant barrier to passage of humid air frombelow pallet upper wall to above, promoting relatively dry foliage 223and relatively moist soil, thereby reducing potential formoisture-related foliage diseases.

FIGS. 2C, 2D—Pallet Assembly Segment

FIGS. 2C and 2D illustrate in detail a segment of an exploded palletassembly 500 associated with one containerized plant 200. Containerizedplant 200 nests along a vertical axis (e.g., axis 202) into containerreceptacle 509 and receptacle 509 support column 518 in turn nests inand is laterally restrained by receptacle 810 of pallet-stiffening grid800. FIGS. 2C and 2D depict incorporation of frustal containers 203,though containers of other shapes are suitable with appropriateadjustments in features of corresponding pallets.

(FIGS. 2C-2H)—Pallet Segment-General

Pallet segments are mutually contiguously coupled at their outerperimeters 510, forming two-dimensional horizontal arrays of segments,producing a pallet 502. Pallet segment of a first embodimentincorporates a thin upper wall 504 with a hole in the center, formingthe upper end of receptacle 509. Coupled indirectly to the perimeter ofthe hole is the upper edge of a thin receptacle side wall 542. Thebottom edge of the receptacle side wall 542 is coupled to a plurality ofequally-spaced segments of thin receptacle bottom wall 521 that extendradially inward. Coupled to the bottom wall 521 segments toward thecontainer vertical centerline is a downwardly protruding hollow palletsupport column 518 with a closed bottom wall 529.

Pallet Segment Funnel/Upper Wall

Upper wall 504 of each pallet segment is in the shape of a funnel thatcollects impinging rain, irrigation water and broadcast liquids andparticulates and conveys them to the container receptacle 509 in centerof funnel. Upper wall 504 also shades side wall(s) 205 of container fromdirect sunlight, substantially eliminating adverse heating of proximaltips of roots 222 of mounted containerized plant 200. Further, uppersurface of upper wall 504 is light colored, increasing reflection ofsunlight toward containerized plant canopy 223, potentially increasingphotosynthesis and plant growth rate. Simultaneously, heating belowupper wall 504 is further reduced. Reduced heating of container reducesrate of soil 219 dehydration, which otherwise is greatest along thecontainer side walls 205, and consequently improves the soil 219 spatialand temporal moisture consistency.

Funnel outer perimeter 510 is hexagonal in a first embodiment, yieldingstaggered rows of pallet segments, though other shapes are within therealm of this invention. FIG. 2A through 2D reflect such a pallet 502having an array of four rows of four segments each, though othercombinations of numbers of rows and segments are certainly within thespirit of this invention. Continuity of upper wall 504 between palletsegments results in a structure sufficiently rigid to remaining stablewith mounted containerized plants 200 under impinging wind and transitmotion that would readily topple stand-alone like containerized plants200. Downwardly extending pallet lip 564 enables pallets to push againstone another in high winds, facilitating pallet position maintenance.

Pallet Segment Funnel Ribs/Overflow Drain Holes

Pallet segment upper wall 504 incorporates stiffening ribs 513, whichare coupled to like ribs on adjoining pallet segments to increaseoverall pallet stiffness.

Excessive accumulation of water on top 221 of soil 219 of mountedcontainerized plant 200, due to excessive rainfall, combined with theexistence of a water seal between pallet receptacle 509 and mountedcontainer 203, is undesirable as such accumulation increases purging ofnutrients resident in soil 219 of containerized plants 200.Consequently, overflow drain holes 540 are incorporated are incorporatedthrough pallet segment upper wall 504. Overflow drain holes 540 are in afirst embodiment arranged to strike a balance between manufacturingease, i.e., achievable with a single vertical punching action, andminimal plan area projection open to impinging falling water and otherapplications. Overflow drain holes are further placed through sides ofribs to minimize hole area projected both toward mounted containerizedplant and up slope of funnel wall 504, thereby minimizing potential forradially outward growing plant foliage and collecting water to enteroverflow drain hole 540. Finally, bottom edge of overflow drain holes540 is located slightly above funnel surface 504 in rib side wall todivert away from overflow drain hole 540 water running down funnel wall504 slope. Thus, water passing through any of the overflow drain holes540 is substantially that forming a part of the water accumulation tothe level of the associated overflow drain holes 540. It is expectedthat irrigation flow/timing are controllable so as to avert passage,i.e. spillage, of irrigation water through overflow drain holes 540. Thevast majority of irrigation water and other liquid and particulateapplications impinging on funnel wall 504 is shed to upper surface 221of soil 219 of containerized plant 200.

Pallet Segment Receptacle Container Lip Recess

Along the perimeter 511 of the upper end of receptacle 509 is an annularrecess 543 of cross sectional area of sufficient size for receivingcontainer lip 209 on installation of containerized plant 200, therebyminimizing accumulation of collected water outside of container lip 209.Recess 543 also incorporates an annular upward-protruding ridge proximalto radially inward perimeter of recess 543 for sealing against acorresponding container surface, described below.

Pallet Segment Receptacle Side Wall

Each container receptacle 509 of a first embodiment is essentially athin-wall cup substantially matching the shape, though slightly largerin corresponding girth, of a container 203 to be received. Enlargedgirth of container receptacle 509 relative to that of mounted container203 ensures outer surface of container side wall 205 does not contactthe inner surface of the container receptacle side wall 542 along itsentire perimeter at any given elevation, thereby preventing wedging ofcontainer 203 in container receptacle 509 and promoting easy removal ofcontainerized plants 200 from pallet 500. Continuous containerreceptacle side wall 542, combined with a small air gap between it andthe container side wall 205 of an installed containerized plant 200produces a thermal insulating layer particularly beneficial during thecold season. Humidification of air in gap arising from pallet integralwater reservoir, described below, further aids soil temperatureregulation, improving root growth environment. Also, continuouscontainer receptacle side wall 542 protects outer surface of containerside wall 205 of containerized plant 200 against soiling while inproduction, resulting in a high-quality nursery product presentation.

Pallet Segment Receptacle Bottom Wall, Ribs, Risers, Container LiftingAccess Holes, Container Drain Holes (Upper), Container Center Seats,Water Reservoir

As shown in FIGS. 2C through 2H, container receptacle bottom wall 521,which extends inward from bottom edge of container receptacle side wall542, has a central hole from the edge of which downwardly protrudes athin side wall 525 of a hollow column 518.

Spaced along interface between receptacle bottom wall 521 and columnside wall 525 are generally equally-spaced gussets 512, which providefor stiffening of said interface and for centering of rows of palletcolumns 518 in respective gaps between fork tines of pallet-handlingmachinery described below. Gussets 512 are arranged to nest withcorresponding and similarly effective gussets 819 or 614 of grids 800 orgrids 600, respectively, when such are incorporated.

Receptacle bottom wall 521 incorporates container lifting access holes545 and drain holes 551, which in a first embodiment are throughupwardly protruding ribs 515 and risers 552, respectively, creating awater reservoir beneath entire installed container, for retainingcontainer drainage up to a level just below bottom of installedcontainer 203 holding containerized plant 200. This feature provides forimproved regulation of temperature of soil 219 in container 203 and forwater pruning of roots 222 protruding from container drain holes 228 and241. Container lifting access holes 545 are at the highest localelevation in order to ensure water does not drain through them andthereby substantially prevents growth of roots 222 of installedcontainerized plants 200 out of container drain holes 228 and 241 andthrough container lifting access holes 545. This leaves containerlifting access holes 545 substantially clear for passage of containerlifting tooling 2654, described below. Temperature regulation includesheat sinking during the hot season and heat sourcing during the coldseason. Cold season heat sourcing, combined with an effectivedouble-wall root containment system, provides an additional degree ofroot ball freeze protection. Upper surfaces of ends of containerreceptacle bottom wall ribs 515 adjoining central hole 522 rise inelevation to provide seats against which sloped center portion 243 ofcontainer bottom wall can rest, limiting sag of container bottom wallcenter portion 244.

In a second embodiment of container receptacle drainage arrangementshown in FIGS. 2G and 2H, container drain hole 551/2 is through a riser552/2 above elevation of receptacle bottom wall 521/2 sufficient tocause receptacle reservoir water free surface 580/2 to be higher thanthe bottom 208 of the installed container 203, thereby maintainingbottom layer of containerized plant soil 219 immersed in reservoir water581. This yields a wicking action that increases the soil moisturespatially upwardly from water contact elevation, improving containersoil moisture retention between irrigation events.

Pallet Segment Receptacle Support Column

Hollow column 518, coupled to and extending downwardly from bottom wall521 of container receptacle 509, supports weight of pallet 502 segmentand mounted containerized plant 203. A thin column wall 529 closescolumn bottom, except where exist optional column drain holes 547through column bottom wall recesses 548. Column side wall ribs 562provide stiffening of column side walls 525 as well as communication ofcolumn drainage between column drain holes 547 and free surface ofoptionally incorporated grid 600. Column side walls 525 are preferablydownwardly converging tapered, facilitating pallet alignment forautomatic assembly and disassembly, described below, and facilitatingpallet 502 molding process.

Columns 518 support bottoms of containers 203 elevated a short distanceabove the pallet mounting surface, promoting consistent containerdrainage control and blockage of rooting of containerized plant intopallet mounting surface, i.e., ground, via roots growing out ofcontainer drain holes 228 and/or 241. It also provides access to beneathbottoms of containers 203 for lifting of pallet assembly 500 by manualor automatic means, minimizing stress on receptacle side walls 542during such lifting. Columns 518 also present to storm water runningalong ground a smaller impact area than a container seated directly onground, thereby reducing water impact forces on pallet 500 relative tothose on a pallet not incorporating columns.

Columns may have substantially rectangular or oval plans that increaselifting tooling, e.g., fork, access area on pallet assembly sides thathave reduced projected distances between adjoining rows of palletsupport columns 518.

(FIGS. 2A-2H, 3A-3G)—Container Container, General

As shown in FIGS. 2A through 2H and 3A through 3H, each plant container203 comprises at least one sidewall 205 coupled along its lower edge toa bottom wall 208 and terminating in an open upper end 204, and is forholding soil 219 and a growing plant 200.

Container, Lip

Upper perimeter of container sidewall 205 incorporates an integralstiffening lip 209 having a section enlarged relative to that ofcontainer sidewall 205 and extending radially outward from containersidewall 205, reinforcing the open upper end 204 of container 203 andproviding a container lifting handle.

Container Side Wall/Pallet Container Receptacle Fit

Side wall of a cylindrical or frustal container is preferably strictlycircular in girth, though may incorporate vertical ribs, providedsufficient wall thickness or circular girdling is incorporated toprevent significant bulging of container girth. Bulging to the extentouter surface of container side wall 205 wedges against inner surface ofcontainer receptacle side wall 542 is unacceptable.

Container, Bottom Wall, Recesses, Drain Holes

Container 203 incorporates an annular upward recess 233 in containerbottom wall. Recess 233 preferably has a generally isosceles triangularsection wherein the angle at its upper vertex is acute. Recess 233 crosssection shape serves a container lifting stabilization role describedbelow. Recess 233 may also serve a soil moisture retention role, actingas a dam blocking gravity flow of water in soil below upper rim ofrecess/dam 233 from one side of recess/dam 233 to drain holes onopposing side of recess/dam 233. Water in soil on side of recess/dam 233opposite container drain hole 228 or 241, exclusively, as applicable,must climb over recess/dam 233 under diffusion/wicking action, againstgravity, in order to reach incorporated drain hole 228 or 241,exclusively, as applicable, and, thus, the rate of soil dehydration inthe affected zone is reduced relative to a zone in gravity communicationwith an incorporated drain hole 228 or 241, exclusively, as applicable.Omission of strictly container drain holes 228 through container bottom,radially outward from recess/dam 233, gives rise to an annular sloweddehydration zone radially outward from recess/dam 233. Omission ofcontainer drain holes 241 strictly through container bottom, radiallyinward from recess/dam 233, gives rise to a frustal slowed dehydrationzone radially inward from recess/dam 233. Incorporation of all containerdrain holes 228 and 241 results in no slowed dehydration zone.

Radial, upward recesses 242 in container bottom wall 208 allow drainagefrom container inner drain holes to flow freely out from beneath anassociated containerized plant sitting on a planar horizontal surface.Upward, outward sloping of drain hole recesses 229 and 243 enables drainholes 228 and 241 to convey drainage from beneath container and to bepunched in a single vertical trimming stroke. Such sloping of outerdrain hole recesses 229 also creates barriers to growth of containerizedplant roots 222 from container drain holes 228 into lifting rod accessholes 545 of pallet container receptacle 509. Also, a plurality ofcontainer inner seats 560 adjoining lifting access holes 545 blockdirect access to container lifting access holes 545 of roots 222 growingfrom container inner drain holes 241.

FIG. 4—Pallet Container Receptacle/Container Lip Sealing

As shown in FIG. 4, an annular seal 553 is formed between container lip209 and a corresponding annular surface of pallet container receptaclerecess 543. Water collected by funnel 504 associated with containerreceptacle, upon accumulating to upper surface 211 of container lip 209,begins flowing into container 203. Annular recess 543 minimizes wateraccumulation prior to spillage of collected water into container 203.Sealing area 553 supports most of weight of mounted containerized plant200, thereby improving seal. Also, outer edge of lip is in closeproximity to recess wall, thereby acting as a filter that keeps debrisaway from sealing area 553. Further, annular trough 561 adjoiningoutside of annular sealing area 553 also facilitates keepingseal-foiling debris away from sealing area 553. Still further, sealoccurs at the top of an annular ridge that contacts bottom of uppermostwall 211 of container lip 209, resulting in minimal pressure drop acrossseal on accumulation of water to top of uppermost wall 211 of containerlip 209, at which point water begins flowing over container lip 209 intocontainer. Thus, contamination of low leakage pressure drop and debrisfiltering from sealing area 553 will result in negligible loss ofcollected water. Optionally, an elastomeric gasket or foam producingmaterial could be applied to (at least in part) upward facing surface(s)of trough 561, providing a further improved sealing surface againstwhich corresponding downward facing surface of container lip 209 wallwould contact. Incidental debris caught in resulting sealing area wouldbe pressed into relatively highly elastic material, thereby failing tokeep sealing surfaces substantially separated, and enabling asatisfactory seal to be achieved.

FIGS. 2A-2H—Pallet-Stiffening Grid

An optional pallet-stiffening grid 800, shown in FIGS. 2A through 2H isprovided as a means to further stiffen pallets against wind, tightlycontrolling horizontal spacing of pallet support columns 518, aidingpallet 500 upper wall 504 locally in remaining substantially parallel topallet mounting surface, maintaining pallet lip 564 outwardly,downwardly sloped in face of high winds, resulting in consistentlydownward, restraining force on pallet 500 in reaction to resultingupward deflection of impinging wind.

An array of hollow, downwardly extending, slightly inwardly convergingtapered pallet column receptacles 810 receive corresponding palletsegment columns 518. Each receptacle 810 has side wall 811 and bottomwall 812. Receptacle 810 is of slightly larger girth at correspondingelevations than that of pallet segment column 518, providing closeregistration of position of pallet 502 to grid 800 on engagement ofpallet segment column 518 into receptacle 810, while avoiding wedgingbetween side walls 525 and 811 of columns 518 and 800, respectively.

Container lifting access holes 815 through receptacle lip 813 of grid800 aligns with corresponding container lifting access hole 545 throughcontainer receptacle. Receptacle flange 813, lip 814 and containerlifting access holes 815 maintain ability of containerized plants 200 tobe lifted from beneath containers 203 in the process of installingcontainerized plants 200 in pallet assemblies 500 and removingcontainerized plants 200 from pallet assemblies 500, with grids 800incorporated as part of pallet assemblies 500.

Spaced along interface between receptacle lip 813 and column side wall811 are generally equally-spaced gussets 819, which provide forcentering of rows of grid receptacles and, thus, pallet columns 518 inrespective gaps between fork tines of pallet-handling machinerydescribed below. Gussets 819 are arranged to nest with corresponding andsimilarly effective gussets 512 of pallets.

Outer edges of receptacle bottom wall 812 incorporate equally-spacedupward recesses 817 having grid drain holes 816. Such an arrangementaverts creation of a vacuum between pallet column 518 and gridreceptacle 810, promoting ready separation of pallets 502 and grids 800during disassembly of pallet assemblies incorporating grids 800.

FIGS. 3A-3G=Pallet Stiffening Grid/Water Reservoir

A second embodiment of a pallet-stiffening grid 600, which incorporatesits own integral water reservoir, is shown in FIGS. 3A through 3G.Webbing 610 between ribs 608 provide for water retention between columns518. Ridges 604 between adjoining grid segments, prevent communicationof drain water between adjoining grid segments, reducing potentialspread of diseases in collected container drainage. Grid drain holes606, through risers 605 upwardly limit the level of water in grid 600.Elevation of risers 605 is below that of upper edge of ridges 604,causing excess accumulated drain water to drain ground without flowingover ridges 604.

Container lifting access hole 603 through grid aligns with correspondingcontainer lifting access hole 545 through container receptacle and isthrough upwardly protruding grid rib 608, at higher elevation than griddrain hole risers 605, thereby averting grid water drainage throughcontainer lifting access holes 603. Such aversion to drainage throughcontainer lifting access holes 603 consequently averts drawing to themroots 222 growing from container drain holes 228 or 241, as applicable.Container lifting access holes 603 maintain ability of containerizedplants 200 to be lifted from beneath containers 203 in the process ofinstalling containerized plants 200 in pallet assemblies 500 andremoving containerized plants 200 from pallet assemblies 500, with grids600 incorporated as part of pallet assemblies 500.

Hollow, downwardly extending, slightly downwardly converging taperedhollow column 602 at center of grid/water reservoir 600 segment receivescorresponding pallet segment column 518. Column 602 has side wall 612and bottom wall 613. Grid segment column 602 is of slightly larger girthat corresponding elevations than that of pallet segment column 518,providing close registration of position of pallet 502 to grid 600 onmating of columns, while avoiding wedging between side walls 525 and 612of columns 518 and 602, respectively.

Spaced along interface between grid webbing 610 and column side wall 612are generally equally-spaced gussets 614, which provide for centering ofrows of grid receptacles and, thus, pallet columns 518 in respectivegaps between fork tines of pallet-handling machinery described below.Gussets 614 are arranged to nest with corresponding and similarlyeffective gussets 512 of pallets.

One configuration of stiffening grid/water reservoir 600 may incorporatesegment perimeter ridges 604 and container lifting hole 603 risers atelevations that upwardly limit the reservoir water free surface 607 tobelow plant container 203 bottom while a second configuration mayincorporate variants of such features that upwardly limit the reservoirwater surface 607 to above plant container 203 bottom, providing forcontinual contact of container soil with reservoir, and associatedwicking

FIG. 5—8×8 Hex Contiguous PA

In the exploded view of FIG. 5 is a first embodiment of a contiguouscontainer receptacle pallet assembly 400, comprising a pallet 402 havinga contiguous container receptacle array, an optional correspondingpallet-stiffening grid 450, and the appropriate number (64) ofcontainerized plants 200. Pallet 402 and grid 450 are constructedsubstantially similarly to spaced pallet 502 and grid 600 or 800, thoughwith accordingly reduced segment centerline distances.

FIG. 6—2×4 Tray Contiguous PA

In the exploded view of FIG. 6 is a first embodiment of a contiguoustray pallet assembly 300, comprising a pallet 302 having a contiguoustwo-dimensional (4×2) tray array and the appropriate number (8) of trays303 of plants. Other combinations are certainly within the spirit of theinvention. Pallet 302 comprises a generally planar horizontal bodyhaving substantially vertically upwardly protruding flat/tray retainingside walls 311 substantially vertically downwardly protruding palletsupport columns 312 and drain holes 307. Pallet support columns 312support pallet 302 and indirectly trays/flats 303 of plants elevated arelatively short distance above surface on which pallet assembly 300 isseated, providing for lifting fork 1142 or 1657 access and having otherbenefits described above. Pallet 302 further incorporates an integrallyformed drip pan/water reservoir 313 for holding contents, typicallyexcess irrigation or rainwater, with its free surface 308 below thebottom of each mounted flat/tray 303 or, alternately, slightly above thebottom of each mounted flat/tray 303. Level of free surface 308 ofcontents 314 of each segment of drip pan/water reservoir 313 is upwardlylimited by drain holes 307 through riser portions 306 the tops of whichare at the desired elevation of the free surface 308 of the drippan/water reservoir contents 314. Pallet 302 provides sufficient waterretention to avert need for separate drip pan/water reservoir. Trays 303are supported relative to free surface of drip pan/water reservoir waterby ribs 315 and receptacle perimeter ledges 316. Perimeter walls 305mark perimeters of receptacles and pallet 302, controlling positioningof trays 303 within pallet 302. While readily incorporated, no specifictray lifting access holes through pallet 302 are shown as lips 310 oftrays are exposed and suitable for mechanized or manual lifting of trays303 from pallet 302.

The container 203/2 shown in FIG. 7 has the first embodiment of acontainer lifting stabilization feature comprising an annular recess 233in container bottom wall 208 and drain holes 241 through sloped portion243 of container bottom wall 244, strictly on container center side ofrecess 233. Recess 233 doubles as a dam, which reduces the rate ofdehydration of soil near container bottom 208, radially outward fromrecess/dam 233, relative to that of soil near container center bottom244. This occurs as water in subject annular zone of soil reduceddehydration rate must diffuse upward against gravity in order to reachdrain holes 241 on opposing side of recess/dam 233. Again, recesses 242provide for passage of drainage from drain holes 241 out from beneathcontainer 203. Also, presence of recesses 229, while not incorporatingpotential drain holes, suggests a common mold could produce containerswith optional drain holes. Recesses 229 are not necessary in the absenceof drain holes through container bottom along container outer perimeter.

The container 203/3 shown in FIG. 8 has annular recess 233 of FIG. 7,but drain holes 228 through sloped portion 229 of container bottom wall241, strictly radially outward of recess 233. Again, recess 233 doublesas a dam, which reduces the rate of dehydration of soil near containerbottom 244, radially inward from recess/dam 233, relative to that ofsoil near container outer bottom 208. This occurs as water in subjectfrustal zone of soil reduced dehydration rate must diffuse upwardagainst gravity in order to reach drain holes 228 on opposing side ofrecess/dam 233. Presence of channel recesses 242 in the absence of drainholes through container bottom radially inward of recess/dam 233, merelysuggests a common mold could produce containers with optional drainholes. Channel recesses 242 are not necessary in the absence of drainholes through container bottom 243, radially inward of recess/dam 233.

The container 203/4 shown in FIG. 9 provides substantially the samefunction as container 203/3 of FIG. 8, except drain holes 227 arethrough container side wall 205 instead of container bottom wall 208.

The pallet segment 502/2 shown in FIG. 10 has a second embodiment of acollected water overflow drainage system, comprising a circular array ofequally spaced overflow drain holes 540/2 through the upper wall of afoliage-deflecting upward protrusion 570/2 extending from receptaclefunnel wall 508, with proximal water diverter 539/2 immediately up slopefrom each hole 540/2. Overflow drain holes 540/2 may be verticallypunched in a single stroke. In this embodiment, overflow drain holes540/2 are not affiliated with stiffening ribs 513/2.

The pallet segment 502/3 shown in FIG. 11 has a third embodiment of acollected water overflow drainage system, comprising a circular array ofequally spaced overflow drain holes 540/3 through the lower, sloped endwall of a water diverter 539/3, each said hole immediately up slope froma foliage diverting upward protrusion 570/3 extending from receptaclefunnel wall 508. Overflow drain holes 540/3 may be vertically punched ina single stroke. In this embodiment, overflow drain holes 540/3 are notaffiliated with stiffening ribs 513/3.

The pallet segment 502/4 shown in FIG. 12 has a fourth embodiment of acollected water overflow drainage system, comprising a circular array ofequally spaced overflow drain holes 540/4 through receptacle funnel wall508, with proximal water diverter 539/4 immediately up slope from eachhole 540/4. Foliage deflection as in earlier embodiments is notnecessary since hole 540/4 is not projected in radial growth directionof plant foliage. Overflow drain holes 540/4 may be vertically punchedin a single stroke. In this embodiment, overflow drain holes 540/4 arenot affiliated with stiffening ribs 513/4.

The pallet segment 502/5 shown in FIG. 13 has a fifth embodiment of acollected water overflow drainage system, comprising a circular array ofequally spaced pairs of overflow drain holes 540/5 through opposingsloped side walls of a corresponding water diverter 539/5. Foliagedeflection as in earlier embodiments is not necessary since holes 540/5are not projected in radial growth direction of plant foliage. Overflowdrain holes 540/5 may be vertically punched in a single stroke. In thisembodiment, overflow drain holes 540/5 are not affiliated withstiffening ribs 513/5.

The pallet segment 502/6 shown in FIG. 14 has a sixth embodiment of acollected water overflow drainage system, comprising a circular array ofequally spaced overflow drain holes 540/6 each through the down slopeend of a corresponding water diverter 539/6. Foliage deflection may beincorporated with an upward protrusion down slope from each hole 540/6,but is not shown. Overflow drain holes 540/6 are radially punched sothat holes 540/6 are not projected vertically, reducing unintentionalspillage of particularly irrigation water and other broadcast liquidsand particulates. In this embodiment, overflow drain holes 540/6 are notaffiliated with stiffening ribs 513/6.

The pallet segment 502/7 shown in FIG. 15 has a seventh embodiment of acollected water overflow drainage system, comprising a circular array ofequally spaced overflow drain holes 540/7 each through the upper,substantially vertical end wall of a water radial drain trough 571/7.Foliage deflection may be incorporated with an upward protrusion downslope from each hole 540/7, but is not shown. Overflow drain holes 540/7are radially punched so that holes 540/7 are not projected vertically,reducing unintentional spillage of particularly irrigation water andother broadcast liquids and particulates. In this embodiment, overflowdrain holes 540/7 are not affiliated with stiffening ribs 513/7.

The pallet segment 502/8 shown in FIG. 16 has a second embodiment of acontainer receptacle 509/8 that is similar to container receptacle offirst embodiment, except comprising ribs 514/8 and otherwise open sides,reducing the amount of material required for construction of pallet502/8. Sealing of pallet container receptacle 509/8 with container isthe same as in the first container receptacle embodiment. While notdepicted in illustration, ribs 514/8 may have contoured cross sectionsfor increased compressive load capacity. Such contouring is limited bypallet stack nesting pitch requirements.

The pallet assembly segment 500/9 shown in FIG. 17 has a thirdembodiment of a container receptacle 509/9 that is significantly moreshallow relative to earlier embodiments and to the mounted container203/2. Container 203/2 is a second embodiment, having a stepped sidewall 205/2, wherein seal 553/9 between container receptacle 509/9 andcontainer 203/2 is achieved at step 231/2, and collected water enterscontainer 203/2 through water inlet holes 234/2 in container side wall205/2, immediately above container side wall step 231/2. Thus, it is notnecessary for collected water 541/9 to accumulate above container lip209/9 in order for collected water 541/9 to enter container. Hence thelower elevation of overflow drain hole 540/9 relative to container lip209/9. Accommodations for container drainage are similar to earlierembodiments. This pallet container receptacle embodiment and containerembodiment render container lip 209/9 above local funnel wall 508, and,thus, accessible for direct lifting. Consequently, there is no need fora secondary container lifting system to extract containers 203/2 frompallet in process of disassembly of pallet assemblies 500/9.

The pallet assembly segment 500/10 shown in FIG. 18 has a fourthembodiment of a container receptacle 509/10 that is shallow relative tothe mounted container 203/3. Container 203/3 is a third embodiment,having an annular sealing step 231/3 adjoining outer bottom corner ofcontainer 203/3 that seals against container receptacle step 511/10,producing seal 553/10. Collected water enters container 203/3 throughwater inlet holes 234/3 in container side wall 205/3, immediately abovecontainer side wall step 231/3. Thus, it is not necessary for collectedwater 541/10 to accumulate above container lip 209/3 in order forcollected water 541/10 to enter container. Hence the lower elevation ofoverflow drain hole 540/10 relative to container lip 209/10. Annularupward recess 233 in container bottom wall blocks direct water flow pathbetween water inlet holes 234/3 and container drain holes 241,preventing excessive soil erosion. This arrangement also results in asoil reduced dehydration rate zone between recess 233 and container sidewall 205/3 with container 203/3 holding containerized plant installed inpallet container receptacle 509/10. Container drainage is through drainhole 241 on container center side of annular recess 233. This palletcontainer receptacle embodiment and container embodiment rendercontainer lip 209/9 above local funnel wall 508, accessible for directlifting. Consequently, there is no need for a secondary containerlifting system to extract containers 203/3 from pallet in process ofdisassembly of pallet assemblies 500/10.

The elevation section view of FIG. 19 illustrates a fourth embodiment ofa seal 553/21 between pallet container receptacle recess 543/21 and acontainer lip 209/21. Lip 209/21 is shown engaged with pallet containerreceptacle recess 543/21 at perimeter 511/21 of hole through palletsegment upper wall 508. Recess minimizes accumulation of water betweenseal area 553/21 and uppermost surface 211/21 of container lip 209/21.Accumulated water is limited to level 541/21 by overflow drain holes(not shown). Container lip 209/21 is rolled after thermoforming tocreate a section approximating a circle for increased stiffness. Suchlip shape also presents a smooth wall 212/21 at sealing area 553/21,better suited for sealing than a cut edge. Pallet segment furtherincorporates ribs 513/21 and 514/21 for increased stiffness. Air gapbetween pallet container receptacle side wall 542/21 and container sidewall 205/21 provide degree of thermal insulation. Rounded outer surfacesof lip 209/21 produce a container having greater comfort in handling.

The elevation section view of FIG. 20 illustrates a fifth embodiment ofa seal 553/22 between pallet container receptacle recess 543/22 and acontainer lip 209/22. Lip 209/22 is shown engaged with pallet containerreceptacle recess 543/22 at perimeter 511/22 of hole through palletsegment upper wall 508. Recess minimizes accumulation of water betweenseal area 553/22 and uppermost surface 211/22 of container lip 209/22.Accumulated water is limited to level 541/22 by overflow drain holes(not shown). Container lip 209/22 is open to facilitate capture ofparticulates and potentially for aesthetic value. Outer lower corner ofouter lower bend in lip 209/22 presents a smooth wall 212/22 at sealingarea 553/22, better suited for sealing than a cut edge. Pallet segmentfurther incorporates ribs 513/22 and 514/22 for increased stiffness. Airgap between pallet container receptacle side wall 542/22 and containerside wall 205/22 provide degree of thermal insulation. Rounded outersurfaces of lip 209/22 produce a container having greater comfort inhandling.

The elevation section view of FIG. 21 illustrates a sixth embodiment ofa seal 553/23 between pallet container receptacle recess 543/23 and acontainer lip 209/23. Lip 209/23 is shown engaged with pallet containerreceptacle recess 543/23 at perimeter 511/23 of hole through palletsegment upper wall 508. Recess minimizes accumulation of water betweenseal area 553/23 and uppermost surface 211/23 of container lip 209/23.Accumulated water is limited to level 541/23 by overflow drain holes(not shown). Container lip 209/23 is folded as shown—typical of a blowmolding process—to increase stiffness. Outer lower corner of outer lowerbend in lip 209/23 presents a smooth wall 212/23 at sealing area 553/23,better suited for sealing than a cut edge. Pallet segment furtherincorporates ribs 513/23 and 514/23 for increased stiffness. Air gapbetween pallet container receptacle side wall 542/23 and container sidewall 205/23 provide degree of thermal insulation. Rounded outer surfacesof lip 209/23 produce a container having greater comfort in handling.

The elevation section view of FIG. 22 illustrates a seventh embodimentof a seal 553/24 formed between pallet container receptacle recess543/24 and a container lip 209/24. Lip 209/24 is shown engaged withpallet container receptacle recess 543/24 at perimeter 511/24 of holethrough pallet segment upper wall 508. Recess 543/24 minimizesaccumulation of water between seal area 553/24 and uppermost surface211/24 of container lip 209/24. Recess 561/24 incorporates an elevatedannular inner rim the top of which provides sealing surface 553/24.Trough between elevated sealing surface and recess outer perimeter511/24 provides a place for debris to settle under gravity, away fromsealing surface 553/24. Accumulated water is limited to level 541/24 byoverflow drain holes (not shown). Container lip 209/24 is folded asshown—typical of a blow molding process—to increase stiffness. Outerlower corner of outer leg of lip 209/24 is in close proximity to recesswall 543/24, filtering debris from entering recess 543/24. Palletsegment further incorporates ribs 513/24 for increased stiffness. Airgap between pallet container receptacle side wall 542/24 and containerside wall 205/24 provide degree of thermal insulation.

The elevation section view of FIG. 23 illustrates an eighth embodimentof a seal 553/25 between pallet container receptacle recess 543/25 and adifferent container lip 209/25. Sealing engagement is similar to that ofFIG. 21.

The elevation section view of FIG. 24 illustrates a ninth embodiment ofa seal 553/27 formed between pallet container receptacle recess 543/27and a container lip 209/27. Lip 209/27 is shown engaged with palletcontainer receptacle recess 543/27 at perimeter 511/27 of hole throughpallet segment upper wall 508. Recess 543/27 minimizes accumulation ofwater between seal area 553/27 and uppermost surface 211/27 of containerlip 209/27. Recess 543/27 incorporates an elevated annular inner rim thetop of which provides sealing surface 553/27. Trough 561/27 betweenelevated sealing surface and recess outer perimeter 511/27 provides aplace for debris to settle under gravity, away from sealing surface553/27. Accumulated water is limited to level 541/27 by overflow drainholes (not shown). Lower inner surface of outer leg of inverted “U”container lip 209/27—typical of a thermoforming process—provides sealingsurface 553/27. Pallet segment further incorporates ribs 513/27 and514/27 for increased stiffness. Air gap between pallet containerreceptacle side wall 542/27 and container side wall 205/27 providedegree of thermal insulation.

FIGS. 25 through 29 illustrate a first embodiment of a chute arrangementfor conveying applications from funnel surface 504 of a pallet 502/28into the open upper end of container 203 under gravity, whereinarrangement comprises flexible, downward, radially inwardly slopedchutes 530/10 attached to funnel wall along perimeter 535/10, thedischarge ends 534/10 of which overhang lip 209/28 of an installedcontainer 203/28. Upper surface 211/28 of container lip 209/28 slopesdownwardly, radially inwardly relative to pallet container receptaclecenter, facilitating conveyance into container 203/28 of materialdischarged by chute 530/10 along free edges 534/10. Such sloping ofupper surface 211/28 of container lip applies in all embodimentsinvolving chutes for conveying materials from funnel surface 504 intocontainers 203/28, as described below. Pallet container receptacle509/28 sides comprise equally spaced ribs 514/28 with open spacesbetween. Ribs 514/28 are coupled at their upper ends to funnel wall ribs513/28 and at their lower ends to receptacle bottom wall ribs 515/28.Such arrangement of ribs 514/28 and open spaces applies in allembodiments involving chutes for conveying materials from funnel surface504 into containers 203/28, as described below.

Focus of FIGS. 26 through 29 are two adjoining, integral flexible chutes530/10 coupled along perimeter 511/28 to funnel wall 508. While only twoadjoining chutes 530/10 are depicted, incorporation of one or more, ascan be reasonably fit between ribs 514/10, is considered intuitive, andsuch is the case for all embodiments, as described below, incorporatingsuch chutes. Chute side walls 531/10 and 537/10 prevent water fromspilling from chute sides. Chute side walls 531/10 between adjoiningchutes are preferably flexible and joined to one another to achieve abellows-type effect, further averting spillage. Downwardly formedgussets 532/10 stiffen joint 511/28 between chutes 530/10 and upper wall508. Downward protrusions 536/10, on contact with radially outwardsurface of container lip 209/28 during container 203/28 removal frompallet assembly, ensure chutes 530/10 deflect outward, clearing lip209/28.

FIGS. 30 through 34 illustrate a second embodiment of a pallet-containerchute arrangement for conveying applications from funnel surface 504 ofa pallet 502/28 into the open upper end of container under gravity,wherein arrangement comprises integral, two-segment, spring hinged,downward, radially inwardly sloped chutes attached to funnel wall 504along perimeter 535/11, the discharge ends 534/11 of which overhang lip209/28 of an installed container 203/28.

Each of two adjoining, integral chutes comprises an upper segment 556/11coupled along perimeter 535/11 and a lower segment 557/11 coupled toupper segment 56/11 along perimeter 538/11. Each of perimeters walls535/11 and 538/11 is thinned by a groove on underside, forming anintegral spring hinge. Protrusion 555/11 extending downward from funnelwall 504 limits outward deflection of chute upper segment 556/11, whileprotrusions 554/11 and 536/11, extending downward from chute uppersegment 556/11 and lower segment 557/11, respectively, limit downwarddeflection of chute lower segment 557/11 relative to chute upper segment556/11. Described deflections are the result of chute interaction withcontainer lip 209/28 on container installation to and removal fromassociated pallet container receptacle. Chute side walls 531/11 preventwater from spilling from chute sides. Folds 537/11 and 538/11 in chuteside walls 531/11 facilitate spring joint flexibility while preventingwater loss from chute sides. Downward protrusions 536/11, on contactwith radially outward surface of container lip 209/28 during container203/28 removal from pallet assembly, ensure chute segments 556/11 and557/11 deflect outward, clearing lip 209/28.

Free molded and trimmed state of chute depicted in FIG. 32 demonstratesno hidden surfaces preventing vertical extraction from mold of moldedpallet with chutes having segments 556/11 and 557/11.

FIGS. 35 through 39 illustrate a third embodiment of a pallet-containerchute arrangement for conveying applications from funnel surface 504 ofa pallet 502/28 into the open upper end of container under gravity,wherein arrangement comprises integral, single-segment, spring hinged,downward, radially inwardly sloped chutes 530/12 attached to funnel wall504 along perimeter 535/12, the discharge ends 534/12 of which overhanglip 209/28 of an installed container 203/28.

Each of two adjoining, integral chutes 530/12 is substantially rigid andis coupled along its upper perimeter by a thinned wall 535/12, which isthinned by a groove on underside, forming an integral spring hinge. Lip203/28 of container being installed into associated pallet containerreceptacle 509/12 contacts side walls 530/12 of chutes 530/12, drivingchutes 530/12 to rotate downward about hinge 535/12, until uppermostsurface 211/28 of container lip 203/28 passes to below discharge edges534/12 of chutes 530/12, at which point container 203/28 becomes seatedin receptacle 509/12. Spring action of hinges 535/12 causes chutes530/12 to rotate back upward, placing discharge edges 534/12 of chutes530/12 over container lip 209/28. A cam 536/12 is integral to andextends downward from each side wall 531/12 of chutes 530/12. Cams536/12 are separated from water discharge perimeter 534/12 so that waterdischarge perimeter is locally the lowest point contacted by dischargingwater and such water will have no surface leading outside of thecontainer to which to cling and thus be substantially spilled.Discharging water therefore, in a worst case, drips vertically fromchute discharge perimeter 534/12 onto downwardly, radially inwardlysloped upper surface 211/28 of container lip 209/28 and splashes largelyinto container 203/28. On removal of container 203/28 from palletcontainer receptacle 509/12, container lip 203/28 contacts cam 536/12,causing chutes 530/12 to again rotate downward until clear of path ofcontainer lip 209/28.

Chute side walls 531/12 prevent water from spilling from chute sides.Folds 537/12 in chute side walls 531/12 facilitate spring jointflexibility while preventing water loss from chute sides.

Free molded and trimmed state of chute depicted in FIG. 39 demonstratesno hidden surfaces preventing vertical extraction from mold of moldedpallet with chutes 530/12.

FIGS. 40 through 43 illustrate a fourth embodiment of a pallet-containerchute arrangement for conveying applications from funnel surface 504 ofa pallet 502/28 into the open upper end of container under gravity,wherein arrangement comprises integral, single-segment, spring hinged,downward, radially inwardly sloped chutes 530/13 attached to funnel wall504 along perimeter 535/13, the discharge ends 534/13 of which overhanglip 209/28 of an installed container 203/28.

Each of two adjoining, integral chutes 530/13 is substantially rigid andis coupled along its upper perimeter by a thinned wall 535/13, which isthinned by a groove on underside, forming an integral spring hinge. Lip203/28 of container being installed into associated pallet containerreceptacle 509/13 contacts side walls 530/13 of chutes 530/13, drivingchutes 530/13 to rotate downward about hinge 535/13, until uppermostsurface 211/28 of container lip 203/28 passes to below discharge edges534/13 of chutes 530/13, at which point container 203/28 becomes seatedin receptacle 509/13. Spring action of hinges 535/13 causes chutes530/13 to rotate back upward, placing discharge edges 534/13 of chutes530/13 over container lip 209/28. A cam 536/13 is integral to andextends downward from discharge edges 531/13 of chutes 530/13. Cams536/13, spring-loaded against and conforming in shape to outer edge ofcontainer lip 209/28, substantially seals against container lip 209/28,directing water clinging to cam 536/13 over container lip 209/28 intocontainer 203/28. On removal of container 203/28 from pallet containerreceptacle 509/13, container lip 203/28 contacts cam 536/13, causingchutes 530/13 to again rotate downward until clear of path of containerlip 209/28.

Chute side walls 531/13 prevent water from spilling from chute sides.Chute side walls 531/13 between adjoining chutes are preferably flexibleand joined to one another to achieve a bellows-type effect, furtheraverting spillage. Folds 537/13 in chute side walls 531/13 facilitatespring joint flexibility while preventing water loss from chute sides.

Free molded and trimmed state of chute depicted in FIG. 43 demonstratesno hidden surfaces preventing vertical extraction from mold of moldedpallet with chutes 530/13.

FIGS. 44 through 46 are section views comparable to section 45-45 ofFIG. 42 and illustrate a fifth embodiment of a pallet-container chutearrangement for conveying applications from funnel surface 504 of apallet 502/28 into the open upper end of container under gravity,comprising an arrangement of integral, single-segment, spring hinged,downward, radially inwardly sloped chutes 530/14 attached to funnel wall504 along perimeter 535/14, the discharge ends 534/14 of which overhanglip 209/28 of an installed container 203/28.

Each of two adjoining, integral chutes 530/14 is substantially rigid andis coupled along its upper perimeter by a thinned wall 535/14, which isthinned by a groove on underside, forming an integral spring hinge. Lip203/28 of container being installed into associated pallet containerreceptacle 509/14 contacts side walls 530/14 of chutes 530/14, drivingchutes 530/14 to rotate downward about hinge 535/14, until uppermostsurface 211/28 of container lip 203/28 passes to below discharge edges534/14 of chutes 530/14, at which point container 203/28 becomes seatedin receptacle 509/14. Spring action of hinges 535/14 causes chutes530/14 to rotate back upward, placing discharge edges 534/14 of chutes530/14 over container lip 209/28. Discharging water, in a worst case,drips vertically from chute discharge perimeter 534/12 onto downwardly,radially inwardly sloped upper surface 211/28 of container lip 209/28and splashes largely into container 203/28. On removal of container203/28 from pallet container receptacle 509/12, container lip 203/28contacts underside of chutes 530/14, causing chutes 530/14 to rotateupward until clear of path of container lip 209/28. On passage ofcontainer lip 209/28 clear of chutes 530/14, chutes 530/14 spring backto free, downwardly, radially inwardly sloped state.

Chute side walls 531/14 prevent water from spilling from chute sides.Chute side walls 531/14 between adjoining chutes are preferably flexibleand joined to one another to achieve a bellows-type effect, furtheraverting spillage. Folds 537/14 in chute side walls 531/14 facilitatespring joint flexibility while preventing water loss from chute sides.

Free molded and trimmed state of chute depicted in FIG. 44 demonstratesno hidden surfaces preventing vertical extraction from mold of moldedpallet with chutes 530/14.

FIG. 47 is a perspective, exploded view of a fifth embodiment of aspaced container pallet assembly 650, incorporating a pallet 652 havingsquare funnels.

In a contiguous-container pallet assembly 400/2 of a second embodimentshown in FIG. 48, containers 203 of containerized plants 200 are heldsubstantially rigidly upright, in a horizontal two-dimensional array ofcontainer receptacles 410/2 integral to contiguous-container pallet402/2, wherein lips 209 of adjoining containers 203 are mutuallycontiguous. FIG. 48 depicts such a pallet 402/2 having an array of eightrows of eight container receptacles 410/2 each, though othercombinations of numbers of rows and container receptacles are certainlywithin the spirit of this invention. Pallet 402/2 comprises a generallyplanar horizontal body having substantially vertically upwardlyprotruding container stabilizing beams 403/2, substantially verticallydownwardly protruding pallet/container support columns 404/2, containerlifting access holes 405/2, and drain holes 408/2. Containerstabilization beams 403/2 are arranged in symmetric patterns aboutvertical axes and form container receptacles 410/2. Pallet/containersupport columns 404/2 in the first embodiment are centered in containerreceptacles 410/2 and support pallet 402/2 and containers 203 ofcontainerized plants 200 elevated a relatively short distance abovesurface on which pallet 402/2 is seated, providing for lifting fork 1142or 1657 access. Such elevation further reduces potential of waterstanding beneath pallet assembly 400/2 to adversely impact supportedcontainerized plants 200. Container stabilization beams 403/2 also actas pallet stiffening ribs extending between adjoining containerreceptacles 410/2. Contiguous-container pallet 402/2 furtherincorporates an integrally formed drip pan 411/2 for holding contents412/2, typically excess irrigation or rainwater, with its free surfacebelow the bottom of the mounted plant container 203. Drip pan 411/2incorporates dike walls 406/2 that segregate drip pan contents 412/2beneath each mounted containerized plant 200, preventing crosscontamination of drainage between containerized plants 200. Level offree surface 409/2 of contents 412/2 in each drip pan 411/2 is upwardlylimited by drain holes 408/2 through riser portions 407/2 the tops ofwhich are at the desired elevation of free surface 409/2 of the drip pancontents 412/2. Lifting access holes 405/2 are disposed similarly tothose incorporated in spaced-container pallet grid 600 described above,enabling containers 203 of containerized plants 200 to be lifted frombeneath in the process of installing containerized plants 200 in palletassemblies 400/2 and removing containerized plants 200 from palletassemblies 400/2. Integral drip pan 411/2 also provides benefitssubstantially the same as those of spaced-container pallet grids 450 and600 described above.

Pallets are preferably molded as single pieces of commodity plastic,e.g., high-density polyethylene (HDPE), polyethylene terephthalate (PET)or polyvinyl chloride (PVC). Post-consumer or post-industrial recycledwaste can be utilized to reduce material costs to the extent associatedmaterial savings are not offset by increased costs of reducedmanufacturing process reliability. Molded plastic pallets, grids andgrid/water reservoirs may be thermoformed or injection molded.Thermoformed pallets may further be of coextruded sheet, enablingincorporation of a relatively thin, sunlight reflective, white orequivalent pallet wall upper layer combined with a relatively thick,carbon black-loaded pallet wall lower layer as an ultraviolet lightprotected, durable structural layer. Thermoforming may further becombined with upstream in-line sheet extrusion for reduced material andenergy costs. Thermoforming lends itself best to thin-wall, generallyplanar products like subject pallets, grids, and grids/water reservoirs,though necessitates a subsequent trimming operation for separation ofparts from plastic processing support skeletons and for blanking holesin parts as needed. Area-specific partial compression molding ispreferably incorporated into thermoforming process to achieveclose-tolerance and other reduced wall thickness where necessary, e.g.,grooves producing spring hinges for pallet chutes and perimeters ofwalls to be trimmed to reduce wear rate of trimming tooling. Increasedreflection of sunlight adds a substantial portion of reflected sunlightto proximal plant foliage while simultaneously substantially reducingheating of mounted container sides and surrounding areas. Sunlightaddition to foliage potentially increases photosynthesis andcorresponding plant growth rate. Reduced container heating correspondsto reduced heating of roots proximal to container sides and to reducedrate of container soil dehydration, thereby increasing container soilspatial and temporal moisture consistency and associated root health.

Injection molded pallets, grids, and grids/water reservoirs have thebenefit of allowing use of lower-cost grades of a given genericmaterial, combined with better wall thickness control. However, morematerial is typically used for a given part, compared withthermoforming, and pallet material would be largely homogeneous by thenature of the process. Consequently, a carbon black-loaded pallet wouldbe molded and subsequently have a sunlight reflective white coatingapplied to its upper side.

Pallets, grids, and grids/water reservoirs may also be formed andblanked out of sheet metal. Corrosion resistance and sunlightreflectivity would either be inherent in the material or be achievedthrough the addition of suitable coatings.

Containers, much like pallets, are preferably molded as single pieces ofcommodity plastic. However, most common container materials accepted inthe industry are high-density polyethylene (HDPE) and polypropylene(PP). Molded plastic containers may be thermoformed, blow molded orinjection molded. Thermoformed containers may further be of coextrudedsheet, enabling incorporation of a relatively thin, sunlight reflective,white or other color container wall outer layer, combined with arelatively thick, carbon black-loaded container wall inner layer as anultraviolet light protected, durable structural layer. Other discussedthermoforming characteristics applying to pallets also apply tocontainers.

Blow molding of frustal, open-top containers usually involvesextrusion/blow molding of a barrel, which is subsequently cut into twosimilar halves—each substantially a container—in a trimming process.Extrusion/blow molding process necessitates injection by a nozzle ofhigh-pressure air into one end of a parison tube sandwiched between twofemale blow mold halves the insides of which together are in the shapeof the subject barrel. Thus, a hole in the center of the bottom of oneof every two containers produced by a conventional extrusion/blowmolding process is a natural result. Therefore, feasibility of onevariant of a container having soil reduced dehydration rate zone, asdescribed earlier, is limited with an extrusion/blow molded container.

Injection molded containers have the benefits and limitations describedfor injection molded pallets and grids/water reservoirs.

Automation System

The substantial gain in stability of position and orientation ofcontainerized plant material offered by incorporation of such plantmaterial into pallet assemblies 300, 400 and 500, and the relativelyrecent development of real-time kinematic global positioning system (RTKGPS) technology gives rise to automation as illustrated in FIGS. 1 and49 through 76 that is in accordance with the invention. RTK GPS is asatellite-plus land-based precision position measuring system accurateto within 10 millimeters horizontally and 20 millimetersvertically—suitable for automated positioning of one or more palletassembly field transfer units (PAFTU's) 1100, pallet assembly transporttrains (PATT's) 1200, and pallet assembly greenhouse transfer units(PAGTU's) 1300. Accuracy of positioning system, with assistance bystrategically located machine sensors, is sufficient to enablesystem-required interaction between PAFTU's and/or PAGTU's, PATT's, anda stationary pallet assembly/disassembly system (PAS) 1500, as in alarge horticultural nursery environment.

RTK GPS as a position determination means does not necessarily precludeincorporation of supplemental position measuring systems, e.g., inertialnavigation, laser-based, wire-in-ground or magnet-in-ground systems, onwhich machine controls rely in few locations where line of sight betweensubject machine and GPS satellites as required for GPS operation is notachievable, e.g. when machine is operating below a roof. Also,strategically placed, supplemental proximity or equivalent sensors inheads of or elsewhere on machinery typically provide fine positionsensing of pallet and/or interacting machine edges, surfaces, and/or theground, to facilitate proper interaction. Autonomous machinery alsoincorporates safety systems such as infrared, vision, and/or motiondetection sensors to ensure machinery work area is properly cleared ofpersonnel and other safety concerns while machinery is actively working.

Pallet Assembly/Disassembly System (PAS)

A first embodiment of a pallet assembly/disassembly system (PAS) 2000 isshown in FIGS. 1, 49 and 50. PAS components are shown in FIGS. 55-61.This system comprises: a pallet assembly central transfer unit (PACTU)5000; two pallet assembly/disassembly units (PAU's), 2100(1) and2100(2), each with three integral PC's; two pallet & gridstacking/de-stacking units (PGSU's) 4500(1) and 4500(2); twocontainerized plant spacing conveyors (CSC's) 1660(1) and 1660(2); twopallet & grid rotating units 5500(1) and 5500(2), a pallet/grid washingunit (PGWU) 5700; a multi-level pallet/grid stack accumulator (PGSA)3500 with integral pallet conveyors (PC's); a PC line conveying pallets,grids, pallet assemblies, pallet stacks and grid stacks among PAS 2000components and through a semi-automatic weeding area 2010.

The preferred implementation of such an automated system of machineryand pallets involves integration of machine controls with the followingcomputer-based systems: plant material growth process database; nurseryinventory and sales order scheduling and control system; and nurseryfinancial control system. Plant growth process includes bills ofmaterials, ideal plant material start time (month), start configuration(plug, clipping, etc.), irrigation schedule, fertilizing schedule,container upsizing schedule, growth duration for designated canopysize/shape, pruning schedule, etc.

Conveyors, General, Physical Description

A preferred embodiment of construction of conveyors employed forhandling pallet stacks, pallets, pallet assemblies, and containers is asdescribed herein.

Conveyors may of the belt/slider bed, belt/roller bed, or synchronousbelt-driven closely spaced, small-diameter roller variety for smoothoperation.

Conveyor belt of each belt type conveyor is composite, comprisingmultiple, closely laterally spaced synchronous belts 1527 for positivecomposite belt surface positioning and belt lateral “walking”elimination. Synchronous belt teeth of belt-type conveyors may also faceup and, thus, provide the conveyed item support surface as conveyormotion is controlled to eliminate slip between belt. Compared todownward-facing, bed-contacting, sliding belt teeth, wear rate of upwardfacing belt teeth is substantially lower. Further, belt can incorporatelow-friction backing, still further reducing belt wear rate.

Roller-type conveyors incorporate relatively closely-spaced, relativelysmall-diameter bed rollers as necessary for relatively small-widthpallet support columns to smoothly span gaps between bed rollers aspallets are conveyed by such a conveyor.

Each conveyor incorporates programmable, numerically controlled servopositioning, determined by a master control system sequence for theactive PAS 1500 operating mode. Such controls also provide programmablevelocity, acceleration, and jerk control, providing for even smootheroperation, consequently virtually eliminating slip between compositebelt and conveyed items, resulting in accurate positioning of such itemsby composite belt while allowing for high-speed operation. All conveyorsoperate reversibly and do so as required for PAS 1500 operating mode.Controls also provide for conveying surface on each side of a transitionbetween adjoining, interacting conveyors to move at the same speed whileconveyed items are in simultaneous contact with both surfaces, stillfurther promoting slip-free contact between conveyor belts and conveyeditems, thereby maintaining high positioning accuracy of conveyed items.Each conveyor incorporates relatively small head and tail sprockets,allowing close spacing of tandem adjoining conveyors, which provides forstable transitioning of relatively small conveyed items between same.Each conveyor also has a relatively large diameter, elongated sprocketdriving the composite belt on the return belt layer generally betweenhead and tail rollers, facilitating drive of relatively large conveyeditems while promoting long belt life. Drive sprocket is flanked by idlerrollers that provide requisite composite belt tensioning and drivesprocket wrap angle. Composite belt drive sprocket is typically coupledto a servomotor through a drive train, comprising a drive train sprocketdirectly coupled to the composite belt drive sprocket, which, in turn,is driven by a gear belt, which, in turn, is driven by a second drivetrain sprocket, which, in turn, is coupled to a servomotor or servo gearmotor, as load dictates. Frame of servomotor/gear motor, as applicable,is fastened to framework against which servomotor/gear motor reacts onimparting torque necessary to move composite belt.

As is typical in heavy-duty, precision positioning conveyorconstruction, all substantially continuously operating rotating jointsincorporate rolling element, e.g., ball, bearings for repeatability.Such bearings are preferably sealed for long life. Use of beltconstruction provides the benefit of minimal system backlash whileoffering long life without the need for lubrication. Thus, conveyoraccuracy is maintained with minimal system maintenance. Sealing ofbearings encloses lubrication within bearing, minimizing tendency oflubricant to attract bearing-life-reducing contamination. Absence ofexposed lubricant further promotes a long-lasting clean machineappearance.

Programmable servo conveyor belt positioning controls also provide forcapture of the position of an item on conveyor relative to the strategicposition along conveyor of an ancillary sensor, e.g., a photoelectricsensor, a narrow beam of which crosses laterally above the belt and isbroken by a passing conveyed item, indicating detection of such item. Adigital representation of belt position is reflected through the drivetrain by the servomotor shaft angle measuring device—typically aresolver with digitizing circuitry, or an encoder. Actuation of conveyorbelt causes to move an item initially having an unknown position,enabling a leading or trailing edge of such conveyed item passing suchsensor to cause sensor to change state, signaling control system.Control system, knowing geometry of conveyed item based on an activerecord obtained from a maintained database, and knowing sensor positionon conveyor, thereby establishes position of conveyed item on receipt ofsensor signal. Once position of item is established on a first conveyor,comparable programmable servo positioning controls of subsequentconveyor belts and related item manipulators compute, and, thus,reliably track item position as item progresses through PAS 1500, withsubsequent item presence detection sensors employed only for itemposition verification and minor compensation, if necessary.

Unless otherwise described, conveyors are situated inmetal—formed/welded/painted/bolted steel or bolted extrudedaluminum—framework that fixes conveyor to ground or an adjoining frame.

Most PC's of first embodiment of PAS 1500 are at least twice the widthof the widest pallet, 302, 402, or 502, grid 800 or grid 600 the PAS1500 is configured to process, in order to convey two of such itemsclosely laterally spaced. CPC's 1660 and 1660′ are of width sufficientto convey containerized plants in the largest diameter containersdesired to be processed by PAS 1500.

Item (Pallet Assembly, Pallet/Grid/Containerized Plant/Tray/Flat)Manipulator Carriages, General

Each manipulator carriage in the PAS 1500, unless otherwise specified,is constructed generally as described herein.

Each manipulator carriage incorporates programmable, numericallycontrolled servo positioning determined by a master control systemsequence for the active PAS 1500 operating mode. Such controls alsoprovide programmable velocity, acceleration, and jerk control, providingfor even smoother operation, resulting in accurate positioning of suchcarriages while allowing for high-speed operation.

Each manipulator carriage in the first embodiment of the PAS 1500 moveslinearly relative to other manipulator carriages or framework to whichsubject manipulator is attached. Relative motion between two manipulatorcarriages or between a carriage and a fixed frame is accommodatedpreferably by a cam follower bearing arrangement on the shorter of thetwo carriages, or of a carriage and frame, in the direction of motion,such cam follower bearing arrangement movably attached to acomplementary track on the longer. Such motion is typically driven by aservomotor, the frame of which is typically mounted to the shorter ofthe two carriages—or of a carriage and frame, as applicable—in thedirection of motion. The shaft of the subject servomotor (or servo gearmotor, as the load dictates) typically mounts a sprocket, which, inturn, drives a gear belt, which, in turn, is fixed at its ends proximalto the opposing ends of the longer carriage. A pair of idler rollersprovides for requisite wrap angle and tensioning of belt around sprocketand any long horizontal stretches of belt in contact with a supportsurface to substantially mute belt vibration.

Alternately, servomotor frame can be mounted to the carriage/framecontaining the track for a movably connected carriage. A timing beltloop between two sprockets proximal to the ends of the subject track andmovable carriage incorporates a clamp that is fastened to one of thetiming belt legs. The shaft of the driving servomotor (or servogearmotor) may be mounted to one of the loop end sprockets, or to aseparate drive sprocket with flanking idler rollers on the unclamped legof the loop. Also, two carriages mirroring one another may be drivensimultaneously by this alternate arrangement simply by clamping onecarriage to one leg and the other carriage to the other leg. These are acouple examples of the use of timing belts and sprockets.

Each substantially slender carriage that must move relativelyperpendicularly to its long side and which is geometrically limited tominimal spacing of bearings in direction of travel necessitatescoordination in movement between its ends with greater mechanicaladvantage than that offered by suggested bearing arrangement. In suchcase, a drive/synchronization shaft extending the length of the carriagemay be incorporated into the drive train. A sprocket and beltarrangement like that described immediately above, is incorporated ateach end of the drive shaft. In a convenient location along the driveshaft, preferably near the center for drive shaft torsional stiffnessbalance, is mounted a third sprocket, which is coupled to and driven bya third gear belt, which is, in turn, coupled to and driven by a fourthsprocket, which is mounted to and driven by the shaft of a servomotor orservo gear motor, as load dictates, the frame of which is fastened tothe slender carriage. A rotary shaft coupling may be incorporated intothe drive shaft near the third sprocket to facilitate change of thethird timing belt. Bearings situated proximal to each sprocket and therotary shaft coupling mount the drive shaft to the slender carriage.Such an arrangement is comparable to rack-and-pinion assemblies coupledto the ends or a long rotary shaft.

Flexible cable carriers, connected between carriages sharing a track/camfollower bearing arrangement, provide for delivery of electrical andfluid power and signals required by nested carriages. Any one ofstrategically located belt break sensors, on detecting a broken belt,signals control system, which automatically executes an appropriateemergency stop algorithm for the situation and presents audible andvisual alarms that queue facility maintenance personnel to resolveissue.

As is typical in heavy-duty, precision positioning machinery, allsubstantially continuously operating rotating joints preferablyincorporate rolling element, i.e., ball, bearings for repeatability.They also are preferably ‘permanently’ sealed for long life. Use of beltconstruction provides the benefit of minimal system backlash whileoffering long life without the need for lubrication. Thus, machineaccuracy is maintained with minimal system maintenance. Bearinglubrication fittings can be provided at customer direction.

Programmable servo positioning controls provide for coordination ofrelative motion between two or more servo controlled carriages, enablingnested carriages to move in desirable paths relative to fixed space orone another, thus, achieving objectives not achievable without suchcoordination, and difficult with manual intervention. A digitalrepresentation of carriage position is reflected through the drive trainby the servomotor shaft angle-measuring device—typically a resolver withdigitizing circuitry, or an encoder. A ‘home’ limit switch/sensor,typically mounted proximal to one end of track on which carriageoperates, is incorporated with servo positioning systems that utilize anincremental quadrature encoder or equivalent pulse train generator withinternal pulse counter for carriage position determination. Thesefeatures are all typically accommodated in today's motion controlsystems.

Linear timing belt-driven motion manipulator carriages that are drivenat fixed inclined angles (including vertical) each typically incorporatea ‘counterbalance’ pneumatic cylinder. A ‘counterbalance’ pneumaticcylinder, as specified here and in several other vertical motionapplications forming parts of this invention, is a pneumatic cylinderconnected to a first machine element—a carriage or frame—and having amovable piston attached to a second machine element, where one machineelement moves in part vertically relative to other machine element.Force applied by compressed air to side of cylinder piston that acts tolift inclined moving machine element provides for substantialcancellation of the effects of gravity on such machine element whileother machine element is either stationary or moves in horizontal planein a gravitational or other body force-producing field. Typically,piston side of cylinder that acts to lift inclined moving machineelement is ported to a closed tank of compressed air, such tank havingvolume substantially greater than that of cylinder to avert unnecessarycompressed air consumption while providing for minimal pressurevariation as piston traverses cylinder, changing combined closed volumeof compressed air. This allows for reduced motor/drive sizing andreduced mechanical energy waste, relative to a non-counterbalancedsystem, to accomplish a given task involving inclined motion.

True mass-based counterbalancing may be incorporated in relativelymassive machine elements that to not move in consistent directionsrelative to a body force-producing field.

Linear motion manipulator carriages that are driven at inclined angleseach also typically incorporate a failsafe brake device that isautomatically applied with the removal of power to it, in an ‘emergencystop’ situation, or with detected breakage of a related carriage drivebelt. Such a brake freezes the position of an inclined manipulatorcarriage relative to the carriage or frame to which the inclinedcarriage is directly movably attached, typically through a cam followerbearing/track arrangement.

Typical manipulator is constructed of metal—formed/welded/painted/boltedsteel or bolted extruded aluminum—framework.

The aforementioned drive techniques are merely examples. Those skilledin the art readily appreciate the myriad of drive type possibilitiessuitable for given tasks, which may involve hydraulics, strict electric,pneumatic, mechanical (wedges/cams, levers, cranks, screws, etc.)

Pallet Assembly Transport Train (PATT)

A first embodiment of a pallet assembly transport train (PATT) 1200,shown in FIGS. 55-56, comprises an autonomously guided traction unit1202 typically towing one or more trailers 1222/1, 1222/2 in tandem withone another. PATT 1200 traction unit 1202 incorporates: servopositioning traction drives 1203 driving traction wheels 1204; a servopositioning steering assembly drive 1207; a PATT 1200microprocessor-based programmable control system 1210, with RTKGPS-capable receiver 1211, GPS base station error correction signalradio antenna 1216, GPS satellite antenna 1212 and, optionally, secondGPS antenna 1214; prime mover 1209; several removable, adjustable-heightplant material transport decks (4 shown, 1239, 1240, 1241, 1242);lightning rods 1230 and grounding electrodes 1231; a forward warningilluminated beacon 1232; headlights 1234; a personnel/obstructiondetection safety sensor 1235; and, trailer coupling 1223. PATT 1200trailer 1222 incorporates a front coupling/tow bar 1224 andthereby-driven steering assembly 1225 mounting two freely rotating frontsupport wheels 1227; two fixed-direction freely rotating rear supportwheels 1228; several removable, adjustable-height plant materialtransport decks (4 shown, 1243, 1244, 1245, 1246); rear coupling/tow bar1223; and, lightning rods 1230 and grounding electrodes 1231. Lasttrailer (1222/2 shown) of PATT 1200, further incorporates rear,illuminated safety beacon 1233.

In first embodiment of PATT 1200, each traction drive 1203 comprises aservo gearmotor coupled to a corresponding traction wheel 1204 through asynchronous belt/sprocket set. Belt/sprocket set are shrouded forsafety. PATT 1200 steering drive 1207 similarly comprises a servogearmotor coupled to a steering assembly 1205 arcuate segment memberthat swivels about a vertical axis centered between two steering wheels1208. Further, a steering belt break sensor, combined with twoside-by-side steering belts, provides steering redundancy, enabling PATTto be safely stopped upon detection of steering belt breakage.

PATT 1200 RTK GPS-capable receiver 1211, receiving GPS satellite radiosignals via two spaced GPS antennas 1212 and 1214 and an RTK GPS errorcorrection signal from system base station 112 via radio antenna 1216,determines PATT 1200 position, and control system 1210, interacting withGPS receiver 1211, subsequently determines heading and attitude of PATT1200.

PATT 1200 must also operate beneath a roof, where PAS 2000 resides, andwhere GPS satellite signals may not. Thus, PATT also incorporates asupplemental guidance system, based on buried wire or magnets,laser-reflector, inertial navigation, or dead reckoning techniquescommonly used for autonomously guided vehicle guidance. PATT controlsystem switches position sensing systems at predefined locations wheretwo position sensing systems are both effective, ensuring PATT isconstantly aware of its position throughout its operating domain.

PATT control system 1210 includes memory and permanent storage in whichreside data and control algorithms pertaining to PATT 1200 operation.Data residing in PATT control system 1210 may include: geometry,configuration and operational status of PATT 1200; layout—includingtopography—of nursery in which PATT 1200 operates (particularly paths onwhich PATT 1200 operates); restrictions, e.g., area reduced speedlimits; and, historical information, e.g. earlier detected PATT pathtopological aberrations, etc. Control algorithms include servo tractionand steering drive position and speed loops, turn maneuvers, positioningmaneuvers for loading and unloading, emergency stop sequences,communication link loss sequences, responses to human-machine interface(HMI) manual control inputs, etc.

Master control system 113, residing at base station 112 of FIG. 1likewise includes memory and permanent storage in which reside data andcontrol algorithms, though on a higher, supervisory control and dataacquisition (SCADA) level than that of PATT 1200. Master control system113 data pertaining to a given PATT 1200 may include: PATT 1200 taskqueue; PATT 1200 operational status, e.g., master control system113—PATT 1200 communication link status, PATT 1200 current position,speed, command responses/deviations, energy/fuel remaining, PATT 1200maintenance calendar, etc. Master control system 113 algorithmspertaining to PATT 1200 include: PATT 1200 destination coordinatesgeneration, PATT 1200 operation scheduling/timing/traffic control,inventory control, PATT 1200 productivity determination, primary HMI,nursery administrative computer system interaction, PATT 1200 algorithmupdates, and system monitoring and fault processing, etc.

PATT 1200 normally operates in automatic mode wherein it followspredefined, computer-generated paths for carrying palletized plantmaterial between loading and unloading points comprising pallet assemblycentral transfer unit 5000 (PACTU, described below) load/unload point ofPAS 2000, a field growing area, a load/unload point proximal to arelatively small, inaccessible greenhouse, potentially inside a largergreenhouse, or some combination of those. Periodically, PATT's 1200 musttransport stacks of pallets and, potentially, grids, between field-and/or greenhouse-based storage areas and PACTU 5000 load/unload pointof PAS 2000.

PATT 1200 may also be operated in manual mode wherein it responds toinputs from an operator via a cable- or radio-linked HMI. An attachableseat may be provided for operator to safely ride on PATT 1200 whilemanually piloting it.

PATT 1200 depicted is battery-powered and incorporates electric,programmable servo drives (servo amplifier/motor packages) foractuation. Actuation could alternately comprise servo valve-controlledhydrostatic transmissions and have a diesel or gasoline engine as aprime mover. An alternator coupled to subject engine of a primarilyhydraulically driven machine supplies electric energy to electricfunctions.

Electric primary drives offer a means to readily return PATT 1200kinetic energy to potential energy, i.e., recharging battery throughservo traction motor generation action during deceleration of PATT 1200,with minimal losses to thermal energy, resulting in a relativelyefficient system, i.e. one requiring relatively the least amount ofenergy, i.e., operating expense, to travel a given distance with a givenload.

Incorporation of positioning servo drives as traction drives providesPATT 1200 with an ability to sense and thereby minimize traction wheelslip, increasing PATT 1200 traction drive efficiency and reducingpotential for PATT 1200 path rut development, particularly during wetPATT 1200 path conditions.

GPS-based positioning and a central, artificially illuminated, PAS 2000also enables system to operate without light, i.e., at night. Lightningrods 1230 and associated grounding wiring and electrodes 1231 reducerisk of damage to PATT 1200 by a stroke of lightning, facilitatingoperation of PATT 1200 in a thunderstorm, thereby still furtherincreasing system productivity.

Pallet Assembly Central Transfer Unit (PACTU)

Note that while most linear track rails throughout invention are shownas simple bars, structure of rails and bearings following themincorporates elements, typically rolling, that prevent normal separationof bearings from track rails, regardless of direction of force appliedto bearings.

A first embodiment of PACTU 5000, shown in FIGS. 49-54 and 57-58F, iseffectively a gantry-based automated forklift, comprising moving nestedcarriages of which are situated generally above PC's 5001 and 5002 ofFIGS. 57-58F. PACTU automatically transfers PA's 300, 400 or 500, asapplicable, between a PC 5001 or 5002 and proximally positioned PATT1200.

PACTU 5000 comprises two stationary frames comprising risers 5011, 5012,5021 and 5022, and lateral beams 5013 and 5023, with three progressivelynested, mutually orthogonal, linear motion carriages culminating in apallet assembly fork 5400. Frame lateral beams 5013 and 5023 incorporatetrack rails 5014 and 5024 traversed by a relatively slender overheadbridge (first carriage, 5050), which is sufficiently high to provide forpassage beneath of a loaded PATT 1200. Bridge 5050 is perpendicular toPC line it spans and is of sufficient length to span: a PATT 1200positioned parallel to and in close proximity to PC line; PC 5001 or5002; and a parking lane for PACTU successive carriages nested below,including PACTU fork 5400. Four frame riser supports 5011, 5012, 5021,and 5022, extending from ground are situated in four corners of frame.PACTU bridge 5050 is movably attached to stationary track rails 5014 and5024 on frame.

Bridge 5050 further incorporates a horizontal second linear track 5070,along length of bridge 5050, to which a second carriage 5100 is movablyattached.

PACTU second carriage 5100 is movably attached to bridge track 5070,providing for movement along bridge 5050 of second carriage 5100. Secondcarriage 5100 may further incorporate a swivel bearing 5108 and driveservo gearmotor 5104 providing for rotation of a third carriage (liftmast) 5150 about a vertical axis. Third carriage 5150 incorporatesvertical linear track 5153, to which a fourth, carriage 5200 (lift stage1) is movably attached.

PACTU fourth carriage 5200 (lift stage 1) is movably attached to PACTUthird carriage 5150 and incorporates a bearing track arrangement 5205movably attached to PACTU fifth carriage 5250 (lift stage 2), whichmounts PACTU fork 5400. Hydraulic cylinder 5155, with its butt attachedto third carriage 5150 and its rod attached to fourth carriage 5200,draws upward on fourth carriage 5200. One end 5156 of each of two belts5157 is attached to bottom of third carriage 5150, while other end 5253of each belt 5157 is attached to fifth carriage 5250. Belts 5157 wrapover tops of respective rollers 5204 such that drawing upward of fourthcarriage 5200 by hydraulic cylinder 5155 causes fifth carriage 5250 tomove upward at twice the rate and distance of fourth carriage 5200.

Fourth and fifth carriages 5200 and 5250, respectively, provide for PAfork 5400 vertical travel between elevation of bottoms of PA's 300, 400or 500, as applicable, seated on PC 5001 or 5002, and elevation ofbottoms of PA's 300, 400 or 500, as applicable, just above uppermostdeck 1203 of PATT 1200, wherein PATT 1200 is situated beneath bridge5050. Tine 5402 lateral adjustment provides for substantially clearpassage of fork tines 5402 between pallet support columns during processof fork engagement with pallets, followed by self-centering of palletson pallet lifting, due to sloped surfaces of gussets between palletcolumns and bottom walls of pallet container receptacles or gridsinteracting with and adjoining edges of fork tines. Such flexibilityprovides for positioning of tines to accommodate variations in geometryof pallets 302, 402, 502, or other, as applicable.

Adjustable fork tines like those of FIGS. 62T and 62U are relativelyslender and of length sufficient to engage two PA's 300, 400, 500, orother, as applicable, closely spaced in tandem along the tines' length.Forks 5400 may also be of sufficient width to provide for engagement ofmore than one ‘column’ of PA's 300, 400, 500, or other, as applicable,along PC 5001 or 5002 length. This enables transfer of more than onepair of PA's 300, 400, 500, or other as applicable, between PC's 5001 or5002 and PATT 1200—over full width of PATT 1200—in one PACTU machinecycle and by accessing PATT 1200 solely from side of PATT 1200 nearestPC 5001 or 5002, as applicable.

PACTU Operation

A PAGTU 5000 transfer-to-PATT 1200 loading process is shown in FIGS.58B-58F. FIG. 58B shows a pair of pallet assemblies 500 seated onconveyor 5002, ready to be transferred to PATT 1200. Fork carriage 5250is in its parking place, adjoining conveyor 5002.

PACTU first carriage (bridge) 5050 provides for fine alignment betweenfork 5250 and PA placement locations longitudinally along PATT 1200 andPACTU-PAU PC's 5001 and 5002. Bridge 5050 may also accommodate multiplePA transition locations.

In assembly mode, pallet assembly transport train 1200 is advanced tocoarsely position an empty pallet assembly space on train 1200 insubstantial alignment with PACTU 5000. PACTU 5000 begins a train loadingcycle by positioning its first carriage 5050 so as to place fork 5250 infine alignment with PA 300, 400 or 500 (500 shown in FIG. 58B) pair onPC 5001 or 5002, on side of PC 5001 or 5002 opposite train 1200. PACTUsecond carriage 5100 then drives fork carriage 5250 into engagement witha pair of PA's 300, 400 or 500, as applicable, seated on PC 5001 or 5002(500 shown in FIG. 58C). PACTU fourth carriage 5200 and fork carriage5250 then lift engaged pair of PA's 300, 400 or 500, as applicable, toslightly above elevation of deck 1203 of available PA space on PATT1200, while bridge 5050 simultaneously moves in direction parallel todirection of PATT travel as necessary to complete fine alignment of forkcarriage 5250 with target PATT space to receive PA's 300, 400 or 500, asapplicable (FIG. 58D). PACTU second carriage 5100 then drives forkcarriage 5250, with load of PA's 300, 400 or 500, as applicable,laterally toward PATT 1200, inserting PA's into target space (FIG. 58E).PACTU fourth carriage 5200 and fork carriage 5250 then lower engagedPA's 300, 400 or 500, as applicable, onto PATT deck 1203 and PACTUsecond carriage 5100 retracts fork carriage 5250 horizontally (FIG.58F), then vertically, as necessary, to its home position.

Unloading of PATT 1200 by PACTU 5000 is simply the reverse of thedescribed loading mode.

Pallet Assembly/Disassembly Unit (PAU) Physical Description

First embodiment of the PAS 2000 incorporates two substantiallyidentical pallet assembly/disassembly units PAU1 2100/1 and PAU2 2100/2,respectively. (Unless otherwise explicitly stated, description of PAU2100 refers to features common to both units.) A first embodiment of PAU2100, shown in FIGS. 59A-59R, comprises: an integral pallet assemblyinfeed/disassembly outfeed conveyor (PAIDOC) 2105; an integral palletassembly outfeed/disassembly infeed conveyor (PAODIC) 2106; an integralcomposite container lifting unit comprising laterally spaced conveyorelements 2450; an integral containerized plant assemblyinfeed/disassembly outfeed conveyor (CAIDOC) 2107; a containerized plantlifting unit (CLU) 2350; and, a containerized plant gripping/transferunit (CGU) 2102. Unless otherwise stated, all PAU 2100 active motioncomponents, including conveyors, are of the servo positioning type.

Adjoining CAIDOC 2107 is a two-zone, servo positioning, containerizedplant spacing conveyor (CSC) 1660 (FIGS. 49, 52, 53, 54), which appliesproper spacing to to-be-loaded containerized plants immediately prior toarrival on CAIDOC 2107 in assembly mode.

Integral Conveyors

PAIDOC 2105, array of CLU conveyor elements 2450, and PAODIC 2106 form aline of PC's that index pallets/pallet assemblies from a first externalPC adjoining one end of PAU 2100, through PAU 2100, to a second externalPC adjoining opposing end of PAU 2100. CAIDOC 2107 is located above andhas flow directions perpendicular to PAODIC 2106. Vertical distancebetween CAIDOC 2107—accounting for CAIDOC 2107 cross section height—andPAODIC 2106 provides for tallest of containerized plants 203 conveyed byPAODIC 2106 to pass below CAIDOC 2107. All conveyors are programmableservo positioning type, having recipe-based indexing sequencesappropriate for pallet assembly type being processed by PAU 2100.

Container Gripping & Transferring Unit (CGU) Phys Desc.

CGU 2102 further comprises: a fixed frame 2104; a first carriage 2150linearly movably attached to frame 2104; a second carriage 2200 linearlymovably attached to first carriage 2150; a third carriage 2250 linearlymovably attached to second carriage 2200; and a gripper array adapter2300 (FIGS. 59H, 59I).

CGU 2102 first carriage 2150 and those nested thereon reciprocallytraverse, on bearings 2153, linear track 2152 horizontal, parallel toflow directions of PC's 2105 and 2106, under the action of servogearmotor 2154 (FIG. 59G), and associated drive components. Drivecomponents, comprising gearmotor-mounted sync belt sprocket 2155, syncbelt 2156, and drive/sync shaft 2158—mounted sync belt sprocket 2157drive drive/sync shaft 2158 (mounted to frame 2104 on bearings notshown). Drive/sync sprockets 2159 and 2160 near ends of drive/sync shaft2158, in turn, drive drive/sync belts 2161 and 2162, the loops of whichare supported at the opposing ends by idler/sync sprockets 2163 and 2164(mounted to frame 2104 on bearings not shown), respectively. Drive beltclamps 2165 and 2166 couple first carriage 2150 to synchronous runs ofdrive belts 2161 and 2162, respectively. Drive belt couplings aresubstantially symmetric lateral to drive direction, minimizing twistingof frame 2104 and first carriage 2150 that results from acceleration offirst carriage 2150 and thereon nested carriages in motion direction offirst carriage 2150. Ends of track 2152 rails incorporate carriageshock-absorbing safety bumpers 2167, which prevent decoupling of CGUfirst carriage 2150 from track 2152 in the event of a drive/sync beltfailure. Further, drive belt breakage sensors cause control system toexecute a carriage smooth-deceleration-to-stop sequence upon detectionof belt breakage.

Container gripper first carriage 2150 movement relative to PAU 2100frame provides for horizontal translation of gripped containerizedplants between container lifting unit (CLU) 2350 (described below)transition point and centerline of CAIDOC 2107. Container gripper firstcarriage 2150 further incorporates vertical linear bearings 2205, whichare movably attached to vertical track 2206 of container gripper secondcarriage 2200.

CGU second carriage 2200 incorporates a vertical track 2206 forreciprocally movable attachment of CGU second carriage 2200 relative toCGU first carriage 2150. Positioning of CGU second carriage 2200relative to CGU first carriage 2150 is achieved by a positioning servogearmotor/gear belt sprocket/gear belt arrangement 2202, combined with apneumatic counterbalance cylinder 2203 and spring-applied, pneumaticrelease failsafe brake. CGU second carriage 2200 movement relative toCGU first carriage 2150 provides for vertical translation of grippedcontainerized plants between elevation of CLU 2350 transition point andCAIDOC 2107.

Container Gripper Adapter Assembly (CGAA) Embodiment 1

A first embodiment (not necessarily preferred) of CGU second carriage2200 further incorporates linear bearings 2260 along its base, which aremovably attached to horizontal track 2261 of CGU third carriage 2250.

A first embodiment of CGU third carriage 2250 reciprocally translatesrelative to CGU second carriage 2200, perpendicular to PAIDOC 2105 flowdirections. Such movement of CGU third carriage 2250 enables containergrippers to align with laterally staggered pallet container receptacles509 occurring in alternating rows of such receptacles 509 in pallets 502having hexagonal container receptacle segments.

A first embodiment of CGU third carriage 2250 mounts a container gripperarray attachment (CGAA) 2300 having a linear array of individual,horseshoe-shaped container gripper yokes 2306. Each gripper yoke 2306 isarcuate and has an inner radius substantially matching that of the bodyof a corresponding frustal container 203 (FIG. 59E) immediately belowthe container's radially outwardly extending lip 209. Wrap of the yoke2306 around container 203 is limited to an amount that enables yoke 2306to be horizontally freely translated into and out of vertical coaxialalignment with associated container 203 on lowering of yoke 2306relative to associated container 203 to a point a minor distance abovethe bottom of the associated container 203, resulting from decreasingassociated frustal container outer diameter corresponding to decreasingelevation relative to the container 203. Array of container gripperyokes 2306 is attachable as an assembly to CGU third carriage 2250,providing for expedient production setup changes. Each container gripperyoke 2306 may pivot a minor amount about a vertically aligned pin 2310proximal to container 203 to allow for minor eccentricity in placementof containerized plant 200 on containerized plant conveyor 2107.Container gripper yokes 2306 are further each pneumatically “centered”their respective pivot pin. Pneumatic centering actuators 2268 areretracted during initial engagement of each gripper yoke 2306 withassociated container 203, providing for “free” pivoting movement of eachgripper yoke 236, thus, reducing contact forces needed for achievingproper engagement between gripper yoke 2306 and container 203.

CGAA Embodiment 2

A second embodiment of the bottom of CGU second carriage 2700, shown inFIGS. 70-72C, contemplates an active, servo positioned gripper lineararray attachment arrangement. In this case, bottom of CGU secondcarriage 2700 incorporates a beam 2703 mounting a horizontal lineartrack 2782/2783 reciprocally traversed by a container gripperleft-hand-side tine array mounting carriage 2730 and a container gripperright-hand-side tine array mounting carriage 2750. Left-hand-side tinearray mounting carriage 2730 comprises: a linear bearing lateral spacerbar 2732; linear bearings 2733, 2734 (not shown), 2737, and 2738 (notshown); left-hand-side tine array adapter assembly left hook 2735 (notshown) and right hook 2739; and, left-hand-side tine array adapterassembly spring-applied/pneumatically-released left latch pin 2736 (notshown) and right latch pin 2740. Right-hand-side tine array mountingcarriage 2750 comprises: a linear bearing lateral spacer bar 2752;linear bearings 2753, 2754 (not explicitly shown), 2757, and 2758; and,right-hand-side tine array adapter assembly left hook 2755 (not shown)and right hook 2759; and, right-hand-side tine array adapter assemblyspring-applied/pneumatically-released left latch pin 2756 and rightlatch pin 2760.

Servo positioning gearmotor 2704, coupled to left-hand-side tine arrayadapter mounting carriage 2730 through sync belt drive sprocket 2705,sync belt 2706, sync belt idler sprocket 2707, and left-hand-side tinearray carriage belt clamp 2743, actuates container gripperleft-hand-side tine array mounting carriage 2730. Similarly, servopositioning gearmotor 2709, coupled to gripper right-hand-side tinearray adapter mounting carriage 2750 through sync belt drive sprocket2710, sync belt 2711, sync belt idler sprocket 2712, and right-hand-sidetine array carriage belt clamp 2763, actuates container gripperright-hand-side tine array mounting carriage.

Attachable to left-hand-side tine array adapter mounting carriage 2730is a container gripper left-hand-side tine array adapter, comprising atine mounting bar 2782, to which are ultimately mounted an array ofcontainer gripper left-hand-side tines 2785. Attachable toright-hand-side tine array adapter mounting carriage 2750 is a containergripper right-hand-side tine array adapter, comprising a tine mountingbar 2792, to which are ultimately mounted an array of container gripperright-hand-side tines 2795. Tines of container gripper left-hand-sideand right-hand-side tine arrays are interleaved, combining to form anarray of container grippers. Right side of each left-hand-side tine 2785incorporates a container position control recess 2786 while left side ofeach right-hand-side tine 2795 incorporates a container position controlrecess 2796, which mirrors recess 2786.

Servo positioning gearmotors 2704 and 2709 drive gripper tine arrayssynchronously in opposite directions for gripping and releasing of arrayof containers holding containerized plant material. Servo positioninggearmotors 2704 and 2709 drive gripper tine arrays synchronously in thesame direction to effect side shifting of the container gripper array.Container control recesses 2785 and 2786 together support each containerby its downward-facing lip surface at four spaced locations along thelip, mirrored about a vertical plane centered between container grippertines 2785 and 2795. Shapes of container gripper recesses enablegrippers to handle square containers in relatively small, i.e., pint orquart, sizes, as well as frustoconical containers in a plurality ofsizes. With gripper recess depicted, side of a small, e.g., pint orquart-sized, cubic (or pyramidal) container nearest gripper assemblybase is held against recess surfaces 2788 and 2798 by recess surfaces2787 and 2797 as gripper tines are driven toward one another. Recesssurfaces 2787 and 2797, which are inclined relative to direction ofgripping motion, also effectively act to center a cubic (or pyramidal)container between tines 2785 and 2795. Also, recess surfaces 2788 and2798 check rotation of a cubic (or pyramidal) container about itsvertical centerline, fixing container orientation. Programmability ofCGU servo drives enables grippers to carefully approach a containerizedplant and to achieve a pre-defined gap complementing container to begripped, maximizing containerized plant handling reliability.

CGAA Embodiment 3

A third embodiment of the bottom of CGU second carriage 2800, shown inFIGS. 73A-D, contemplates an active, servo positioned gripper lineararray attachment arrangement. In this case, bottom of CGU secondcarriage 2800 incorporates a beam 2803 mounting a horizontal lineartrack 2814/2815 reciprocally traversed by a container gripperleft-hand-side tine array mounting carriage 2820 and a container gripperright-hand-side tine array mounting carriage 2850. Mounted to right endof beam is servo positioning gearmotor 2804, on the shaft of which ismounted a sync belt drive sprocket 2805, which mounts one end of syncbelt 2806 loop, the other end of which, in turn, is captured by syncbelt idler sprocket 2807, proximal to the middle of beam 2803. Mountedto left end of beam is servo positioning gearmotor 2809, on the shaft ofwhich is mounted a sync belt drive sprocket 2810, which mounts one endof sync belt 2811 loop, the other end of which, in turn, is captured bysync belt idler sprocket 2812, also proximal to the middle of beam 2803.

Container gripper left-hand-side tine array mounting carriage 2820 ismovably attached to linear track 2814/2815 via linear bearings 2831,2832 (not shown), 2835, and 2836 (not shown), which are mounted to acontainer gripper left-hand-side tine mounting bar/track 2830.“C”-shaped mounting bar/track 2830 is attached to, and thereby drivenby, container gripper left-hand-side tine array mounting carriage drivebelt 2806 via clamp 2841, which protrudes through and traverses slot2816 through beam 2803. Container gripper right-hand-side tine arraymounting carriage 2850 is movably attached to linear track 2814/2815 vialinear bearings 2861, 2862 (not shown), 2865, and 2866 (not shown),which are mounted to a container gripper right-hand-side tine mountingbar/track 2860. “C”-shaped mounting bar/track 2860 is attached to, andthereby driven by, container gripper right-hand-side tine array mountingcarriage drive belt 2811 via clamp 2871, which protrudes through andtraverses slot 2817 through beam 2803.

Container gripper left-hand-side tine 2920 incorporates a mounting barmating portion having hooks 2922 and 2934 which cause tine 2920 to becaptured inside perimeter of “C” section of mounting bar/track 2830(FIG. 73D). Latch 2923 incorporates a cam 2924, loaded against insidewall of “C”-section mounting bar/track 2830 by spring 2926 acting onlatch torque arm 2925 to create tightly wedged coupling of gripper tineattachment 2920 with mounting bar/track 2830 Releasing of gripper tineattachment 2920 is accomplished by squeezing of cam release arm 2927against cam release backup arm 2928 and sliding of left-hand-side tine2920 from one end of mounting bar/track 2830. Hook adapter plate 2929adapts left-hand-side tine mounting portion to left-hand-side tine 2930.Right-hand-side tine attachment 2940 mounts similarly, except toright-hand-side tine mounting bar/track 2860.

Third embodiment enables a plurality of pallet-container configurationsto be handled (not simultaneously) by one container gripper assemblymerely by repositioning of container gripper tine attachments on CGUand, if necessary, addition or removal, of container gripper tineattachments to or from CGU, respectively.

Servo positioning gearmotors 2804 and 2809 drive gripper tine mountingbar/tracks 2830 and 2860 synchronously in opposite directions forgripping and releasing of array of containers holding containerizedplant material. Servo positioning gearmotors 2804 and 2809 drive grippertine arrays synchronously in the same direction to effect side shiftingof the container gripper array.

Container Lifting Unit (CLU) Physical Description

Water collecting design of pallet assemblies results incorporated plantcontainers that are not exposed for gripping or handling without asecondary means of lifting containers at least partially out of pallets.Consequently, a containerized plant lifting unit (CLU) 2350 forms a partof PAU 2100. CLU 2350 is situated in part in a relatively narrow gapbetween PAIDOC 2105 and PAODIC 2106 and operates generally within asubstantially horizontal, relatively slender, frame 2352 mounted toframe 2104 of PAU 2100.

Substantially along the top of CLU 2350 frame 2352 is a linearhorizontal track 2402 to which CLU first carriage 2400 is movablyattached via linear bearings 2415. A relatively short, integral,composite third pallet conveyor (CLUPC) is formed of an array oflaterally spaced conveyor elements 2450 clamped to CLU first carriage2400. Track 2402 is lateral to PAIDOC 2105 flow directions, and providesfor shuttling of CLU first carriage 2400 to substantially one side ofPAU 2100. Lateral shifting of CLU first carriage 2400 is actuated byservo positioning gearmotor 2403 (FIG. 59G) coupled to CLU firstcarriage 2400 through sync belt drive, comprising sync belt drivesprocket 2408, sync belt 2410, and idler rollers 2412. Sync belt 2410 isopen-ended and coupled to opposing ends CLU first carriage 2400.Individual conveyor elements 2450 can be forcibly slid along length ofCLU first carriage 2400, providing for adjustment of spacing betweenelements to account for differing lifting tooling geometry and spacing.

Conveyor elements 2450 (FIG. 59F illustrating one in a longitudinalvertical section) each comprise a splined sleeve 2453, a sync belt drivesprocket 2454, a sync belt 2455, a sync belt support bed 2456, conveyorhead 2457 and tail 2458 sync belt idler sprockets, an idler roller 2452,and a tensioning roller 2459.

Alternately, conveyor element 2450 belt is inverted and associatedrollers and sprockets are swapped, and tensioning roller and drivesprocket positions swapped. This arrangement results in sync belt teethproviding the conveying surface. Such an arrangement reduces wear rateon belt teeth as theoretically no slip occurs between teeth and conveyedworkpieces. Also, a low-friction belt backing may be applied to reducebelt-bed sliding friction. In earlier configuration, unless belt ismodified, potentially at significant expense, e.g., to yield a “T” crosssection and conveyor element side rails provide belt support, whereinbelt teeth do not contact, and, thus, slide against, conveyor bed whilesupporting weight of conveyed workpieces, belt teeth bear workpiece loadwhile sliding, yielding a relatively high wear rate of belt teeth.

Conveyor elements 2450 are actuated by a servo positioning gearmotor2417 through a coupling 2418 and common splined shaft 2419. CLU firstcarriage 2400 and thereon mounted conveyor elements 2450 may be drivento side of PAU 200 to provide for vertical insertion and removal ofcontainer lifting tooling that mounts below CLU first carriage 2400conveying surface. Positions of conveyor elements 2450 are adjustedautomatically for each new production setup by CLU first carriage 2400positioning of each conveyor element 2450 in an element gripping unit2353, which momentarily grips and effectively fixes the position of agiven conveyor element 2450 in free space while the CLU first carriage2400, to which conveyor element is mounted, is driven in free space,relative to the conveyor element 2450. Control system maintains CLUfirst carriage 2400 and conveyor element gripping unit 2353 geometry,conveyor element 2450 current and subsequent positions, and associatedmotion algorithms as required for automatic position changes.

Nested in CLU 2350 frame 2352 is a CLU second carriage 2500 thatperiodically reciprocally traverses a linear, vertical track, driven bypositioning servo controlled hydraulic actuators 2501 and 2502, whichprovide a portion of the linear guidance. Vertical motionsynchronization of the four corners of CLU second carriage 2500 isaccomplished with arrangement of sync belts 2508, 2509, 2510, and 2511,sync belt sprockets 2506 and 2507, idler rollers 2512 and 2513, syncshaft 2503, and sync shaft 2503 support bearings (not shown). CLU secondcarriage 2500 further incorporates a linear horizontal track 2514 alongthe length of CLU second carriage 2500 along which a CLU fourth carriage2600, discussed below, periodically, reciprocally traverses.

Also nested in CLU 2350 frame 2352 is a CLU third carriage 2550 thatperiodically reciprocally traverses a linear horizontal track 2563perpendicular to PAIDOC 2105 conveyor flow directions, driven by servopositioning gearmotor 2552 through a drive train comprising shaftcoupling 2553, upper sync belt drive sprocket 2557, upper sync belt2559, upper sync belt idler sprocket 2561, drive/sync shaft 2554, lowersync belt drive sprocket 2558, lower sync belt 2560, lower sync beltidler sprocket 2562, and drive/sync shaft 2554 support bearings (notexplicitly shown). Downward extending guide rails 2601 and 2602 providevertical surfaces against which guide bearings 2604 (FIGS. 59D, E) and2605 (FIG. 59H) mounted to a CLU fourth carriage 2600, described below,run, synchronizing horizontal motion of CLU third carriage 2550 and CLUfourth carriage 2600. A CLU container lifting column guide plate 2670portion of a CLU container lifting adapter assembly (CLAA) 2650 isfastened to CLU third carriage 2550 via an array of spring-applied,pneumatically released latches 2567 situated along the seat of guideplate 2670. Nested in CLU second carriage 2500 and CLU third carriage2550 is a CLU fourth carriage 2600. CLU fourth carriage 2600 bearings2603 and 2604 slave CLU fourth carriage to elevation of CLU secondcarriage 2500 and lateral position of CLU third carriage 2550. A CLUcontainer lifting column drive plate 2652 portion of CLU containerlifting adapter assembly 2650 is fastened to CLU fourth carriage 2600via an array of spring-applied, pneumatically released latches 2606situated along the seat of drive plate 2652.

Arrangement of carriages yields relatively low mass of components thatmust shuttle horizontally each machine cycle to align lifting columnswith staggered pallet container receptacles in alternating rows ofhexagonal pallet container receptacle segments. This reduces onframework reaction forces and associated motor loads.

Container Lifting Adapter Assembly (CLAA)

Each container lifting adapter assembly 2650 comprises a containerlifting column drive plate 2652 and a container lifting column guideplate 2670. Drive plate 2652 and guide plate 2670 are horizontallysituated with drive plate 2652 spaced below and normal to guide plate2670. Mounted on drive plate 2652 is a linear array of slendersame-height columns 2654 or groupings 2653 of columns extending upwardfrom drive plate 2652. Lifting columns pass through corresponding holesin complementary lifting column guide plate 2670.

During CLU 2350 operation, drive plate 2652 is latched to andconsequently matches motion of CLU fourth carriage 2600 while guideplate 2670 is latched to and consequently matches motion of CLU thirdcarriage 2550. Fourth carriage 2600 with drive plate 2652 providesvertical upward thrust and position control of lifted containers ofplants while third carriage 2350 with guide plate 2670 ensure upper endsof lifting columns 2654 are accurately aligned with container liftingaccess holes 545 in pallets 502 (FIG. 59E), holes 815 in grids 800,and/or holes 603 in grids/grids 600 (FIG. 59E), on initial liftingcolumn 2654 engagement. Container lifting columns 2654 are arranged topass through gaps between adjoining CLUPC conveyor elements 2450, whichare spaced to substantially align with and support centers of palletcontainer receptacle support columns 518. Conveyor elements 2450 may be‘doubled up’ to support relatively large pallet container receptacles,and consequent heavy containerized plants. Further, conveyor elements2450 not required for supporting a pallet of a particular configurationmay be positioned in gaps between pallet container receptacle supportcolumns 518 or to side of PAU PC operating area.

In the case of frustal or cylindrical containers, container liftingadapter assemblies 2650 incorporate for each container in a row ofspaced pallet container receptacles a circular array 2653 of at leastthree preferably six equally spaced, equally long lifting columns 2654that are attached to and extend upward from container lifting driveplate 2652, through corresponding holes in the container lifting columnguide plate 2670. In a case in which a stabilization groove 233 isincorporated in the bottom of and concentric with each container 203,the diameter of the circular array 2653 of container lifting columns2654 matches that of the groove 233 in the container bottom. Also, inspaced container receptacle pallets 502, the pattern of containerlifting columns 2654 on the container lifting drive plate 2652 matchesthe corresponding pattern of lifting access holes 545 in a row ofcontainer receptacles 509 in a pair of pallets 502 spaced laterallyclosely on the CLU conveyor. There is consequently no restriction onrotational orientation of a mating container about its verticalcenterline for proper mating of lifting columns 2654 with groove 233 ofeach such container.

Also, for spaced container receptacle pallets 502, the pattern in planof container lifting columns 2654(1) on the container lifting driveplate 2652(1) matches that of lifting access holes 545 in a row ofcontainer receptacles 509 in a pair of pallets 502 spaced laterallyclosely together on the CLU conveyor. For contiguous containerreceptacle pallets 402, the pattern of container lifting columns 2654(2)on the container lifting drive plate 2652(2) matches the correspondingpattern of lifting access holes in a row of container receptacles in apair of pallets spaced laterally closely together on the CLU conveyorexcept reflecting the absence of every other pallet containerreceptacle. Such is also the case for tray/flat pallets, which can beconsidered a variant of contiguous container receptacle pallets.

In such case the upper end of each container-lifting column 2654 is inthe general shape of a spade 2655 that matches an arcuate segment of thecontainer bottom groove 233 mating with the lifting column 2654. Largedepth of groove 233 relative to its section width ensures upper andlower contact surfaces between groove 233 and engaged lifting column2654 interfere with free tipping of lifted container 203, resulting instable lifting in the event of container side loading, as may resultfrom entanglement of adjoining plant canopies during containerized plantremoval. Container lifting columns 2654 can be cylindrical, enablingincorporation of circular, normally blanked container lifting accessholes through pallets and grids, resulting in relatively low productioncosts.

In a case in which no stabilization groove is incorporated in the bottomof each container, the diameter of the circular array of containerlifting columns is preferably approximately that of the outer perimeterof the container bottom. In this case the upper ends of the containerlifting columns are “L”-shaped, wherein the horizontal leg points towardthe center of the container bottom and the vertical leg extends a minordistance upward along the side of the container on engagement ofcontainer lifting columns with containers. Such container liftingcolumns necessitate substantially larger container lifting access holesthrough pallets and grids and consequent difficult, oblique trimming ofpallets in production of container receptacles, resulting in relativelygreater production costs.

In a case in which container plans are noncircular, giving rise tofinite relationships rotationally about common vertical centerlinesbetween pallet container receptacles and associated mounted containers,an otherwise circular groove in the bottom of a container would bereplaced by one or more tapered recesses. In this case, for smallercontainers, a single tapered recess of noncircular plan, e.g., apyramid, in and concentric with the container bottom engaged by a singlecontainer-lifting column yields requisite container lifting stability.Noncircular plan of single container lifting column per containerensures associated container remains rotationally fixed about itsvertical centerline while gripper array is in the process of retrievingit.

PAU Operation CGU/CGAA Embodiment 1

In PAU having first embodiment of CGU/CGAA arrangement (FIGS. 55-56),CGAA 2300 corresponding to pallet 502 configuration to be processed isretrieved and installed, as described above.

CGU/CGAA Embodiment 2

In PAU having second embodiment of CGU/CGAA arrangement (FIGS. 70-72C),CGAA 2780/2790 corresponding to pallet 502 configuration to be processedis retrieved and installed, similarly to process for first embodiment.

CGU/CGAA Embodiment 3

In PAU having third embodiment of CGU/CGAA arrangement (FIGS. 73A-D),CGAA 2920/2940 gripper tines are positioned corresponding to pallet 502configuration to be processed.

Common

Also, prior to start of production, CLU conveyor elements 2450 arepositioned typically to align with predefined lateral positions ofcenters of pallet container receptacles 509 across PAIDOC 2105 prior tostart of production run. For larger containers, CLU conveyor elementsmay be “doubled up” beneath each pallet receptacle to accommodate therelatively greater weight/mass involved, given the lower number ofreceptacles 509 involved and relatively greater spacing betweencontainer lifting columns lifting individual containerized plants.

In production processing of spaced container receptacle pallets 502(FIGS. 2, 3, 55-56), a full pallet row of containerized plants isassembled or disassembled, depending on PAU operating mode, in onemachine cycle. In processing of contiguous receptacle pallets 402 (FIG.5), including tray/flat pallets 302 (FIG. 6), half of a pallet row ofcontainerized plants, i.e., every other containerized plant in a row, isassembled or disassembled, depending on PAU operating mode, in onemachine cycle, given space required for grippers to access and liftcontainerized plants 200 by the lips of their containers or trays/flatsof plants 303 by their lips, as applicable.

In processing of hexagonal container receptacles, whether spaced orcontiguous, wherein alternating rows of container receptacles arelaterally staggered, appropriate CGU and CLU carriages shuttlereciprocally, laterally relative to PAIDOC 2105 flow direction eachmachine cycle for proper alignment between receptacles, containergrippers and container lifting columns. Such reciprocal lateralshuttling also occurs in order to process alternating contiguouscontainer receptacle pallets 402, as well as flat/tray pallets 302,i.e., regardless of whether pallet container receptacle rows arestaggered, as stated above.

In processing pallet assemblies, e.g., 500, in which a secondary meansis necessary to expose container lips 209 for lifting of containers 203,container lifting columns 2654 engage bottoms 216 of plant containers203 situated in pallet container receptacles 509 where container bottoms216 are exposed through container lifting access holes 545 in bottoms ofpallet container receptacles 509, and through lifting access holes 603in separate grids 600 (or lifting access holes 815 in grids 800), ifincorporated. In processing container pallet assemblies that presentexposed lips for container lifting, container lifting columns 2654simply facilitate freeing containers 203 from respective palletcontainer receptacles.

In pallet assembly mode, as shown for spaced container receptaclepallets 502 in FIGS. 59R-J, (i.e., in reverse order), an array ofproperly spaced flats/trays 303 of plants or containers 203 holdingindividually containerized plants 200, proximal to end of CAIDOC 2107,is gripped (FIG. 59Q) by corresponding array of container grippers 2306(in first embodiment (FIGS. 59A-E); 2785/2795 in second embodiment(FIGS. 70-72C); 2930/2960 in third embodiment (FIGS. 73A-D)). The arrayis then: lifted slightly (FIG. 59P); translated horizontally to side ofCAIDOC 2107, to vertical alignment with corresponding array of emptypallet receptacles 309, 140 or 509, as applicable, momentarily situatedin PAU 2100(2) (FIG. 59N); and, lowered to an elevation whereinflats/trays 303 of plants or containers 203 of individuallycontainerized plants 200 are engaged with tops of elevated containerlifting columns, just above empty pallet receptacles 309, 140 or 509,and which fourth carriage 2600 of container lifting unit 2350 has drivenup to such a position (FIG. 59M).

Over substantially the same time period, PAIDOC 2105 receives emptypallets, potentially nested in grids, from an adjoining first PC, anddrives, in an indexing fashion, such pallets toward containerizedplant-pallet assembly area of PAU 2100, largely asynchronously withassembly action of containerized plant-pallet assembly area of PAU 2100,though substantially synchronously with lateral shuttling of CLU third2550 and downwardly retracted fourth 2600 carriages and associatedcontainer lifting assembly adapter 2650 (FIGS. 59P, N). CLU conveyorelements 2450 index synchronously with adjoining PC's (PAIDOC 2105 orPAODIC 2106) while pallets are in simultaneous contact. PAODIC 2106receives in an indexing fashion loaded portions of pallets from PAU 2100assembly area (CGU/CLU combination), and ultimately conveys completedpallet assemblies 500 to PC adjoining PAODIC 2106.

Container lifting columns 2654 extend upward through container liftingaccess holes 545 and, if applicable 603 or 815, such that their upperends are positioned against the bottom of the array of flats/trays 303of plants or containers 203 of individually containerized plants 200 toengage pallet container receptacles 309, 140 or 509, as applicable(FIGS. 59A-E, M). Grippers 2306 (in first embodiment); 2785/2795 insecond embodiment (FIGS. 70-72C); 2930/2960 in third embodiment (FIGS.73A-D)) then release flats/trays 303 of plants or containers 203 ofindividually containerized plants 200, as applicable, and CLU fourthcarriage 2600 retracts downward (FIG. 59J), completing transfer of arrayof flats/trays 303 of plants or containers 203 of individuallycontainerized plants 200 to respective pallets 302, 402 or 502, asapplicable, then to a point wherein tops of container lifting columns2654 have receded through gaps between conveyor elements 2450 to belowconveyor elements 2450 upper surface to allow for indexing of palletassemblies 300, 400 or 500, as applicable, by PAIDOC PC 2105, CLUconveyor elements 2450, and PAODIC 2106 (similar to FIGS. 59P, N). WhileCLU fourth carriage 2600 is fully retracted and PAIDOC PC 2105 andPAODIC PC 2106 are subsequently indexing pallets 302, 402 or 502, asapplicable, to load the next empty receptacles, container grippers 2306(in first embodiment); 2785/2795 in second embodiment (FIGS. 70-72C);2930/2960 in third embodiment (FIGS. 73A-D)) are moving up to retrieveanother array of flats/trays 303 of plants or containers 203 ofindividually containerized plants 200, which CPC 1700 is simultaneouslyconveying into position for retrieval. At substantially the same time,CLU container lifting columns shuttle laterally to align with next setof empty pallet container receptacles.

Pallet disassembly mode, depicted by FIGS. 59J-R (in the orderindicated), is simply the pallet assembly mode operating in reverse.Container gripper unit 2102 periodically reciprocally lowers containergrippers 2306 to an elevation above top of pallets 302, 402 or 502, asapplicable, where lips of flats/trays 303 of plants or containers 203 ofcontainerized plants 200 being extracted become readily accessiblethrough lifting of such flats/trays 303 of plants or containerizedplants 200 by CLU container lifting columns 2654. On gripping ofcontainers 203, CGU 2102 transfers associated containerized plants 200to CAIDOC 2107 and CLU container lifting columns 2654 retract. Once CLUcontainer lifting columns 2654 are clear of PA's 300, 400 or 500, asapplicable, PAIDOC 2105, CLU conveyor elements 2450 and PAODIC 2106,index by one pallet container receptacle row toward PGWU 5700.

PAU control programming can, as part of assembly and/or disassemblymachine cycles, cause PAU container gripper array to be positionedagainst upper surfaces of pallets adjoining row of container receptacles(a) about to receive containerized plant material and/or (b) from whichplant material is being extracted.

In the case of pallet container receptacles about to receivecontainerized plant material, such momentary positioning of PAUcontainer gripper array prevents lifting of pallets that may otherwiseresult from incidental contact between container lifting columns andedges of associated container lifting access holes through pallets, and,if applicable, grids, as container lifting columns pass upward throughcontainer lifting access holes in pallets (and, if applicable, grids).In the case of containerized plant material being extracted, suchmomentary positioning of PAU container gripper array further preventslifting of pallets resulting from incidental friction between pallet andcontainerized plant material being upwardly extracted frompallet—friction that may otherwise cause pallet to be lifted along withcontainerized plant material being upwardly extracted from pallet.

Such incidental friction may result from accumulation of debris incontainer lip-supporting trough along upper perimeter of palletcontainer receptacle, outside of container lip. It may also result fromminor deformation of container side wall(s) and/or pallet containerreceptacle side wall(s) (e.g., elliptical instead of round in plan),which cause incidental contact between such respective side walls. Theseare but a couple of examples of pallet-containerized plant materialfriction sources and are not intended to be all-inclusive.

Lastly, extraction of containerized plant material from pallets may befurther facilitated by minor differences (e.g., approximately ¼ inch)between; (a) the height of an array of container lifting columnsassociated with a first containerized plant in a given row beingextracted, and (b) the height of an array of container lifting columnsassociated with a second containerized plant adjoining said firstcontainerized plant in the subject row being extracted; relative tocontainer lifting adapter drive plate. Such variation in heights ofcontainer-associated container lifting column arrays reduces the numberof containerized plants experiencing initial separation from the palletsat any given temporal instant. It also results in a correspondingconcentration of pallet-containerized plant initial separation forcesfor overcoming pallet-containerized plant friction. The difference inheight between the array of greatest elevation and the array of leastelevation in a given container lifting adapter assembly is, however,sufficiently small to ensure containerized plant material can bereliably transferred to and from containerized gripper array, which issituated substantially in a horizontal plane (and, therefore, does notnecessarily have corresponding gripper-to-gripper elevation variation).

Variation in gripper-to-gripper elevation relative to gripper adapterbase may alternately complement variation in container lifting columnarray elevation relative to container lifting drive plate. If so,gripper-to-gripper elevation variation will be sufficiently small toensure simultaneously gripped containerized plant material can bereliably transferred to and from a common horizontal planar (i.e., astationary conveyor) surface.

Automatic CGAA & CLAA Change & CLU Conveyor Element Positioning

Programmable controls, electro-pneumatically actuated latches andservo-driven conveyors and carriages enable switching of CGAA 2300 andCLAA 2650 fitting one pallet configuration to those fitting another.FIGS. 59G and H depict a PAU 2100 with its CGAA 2300 and CLAA 2650removed from their working mounts and placed in a storage fixture 2680,which maintains the set as a single unit for conveying to and storage inPGSA 3500. Automatic process of extracting CGAA 2300 and CLAA 2650 fromtheir working mounts comprises: retrieving from PGSU 3500 storagefixture 2680(1) for to-be-removed tooling and storage fixture 2680(2)(not shown) holding to-be-installed tooling, and conveying same toPAIDOC 2105 and PAODIC 2106, respectively; shuttling CLU first carriage2400 and thereon mounted CLU conveyor elements 2450 to one side of PAU2100, clear of space above CLAA 2650; fully downwardly retracting CLUsecond carriage 2500 and centering CLU third carriage 2550 (and slavedfourth carriage 2600) mounting CLAA 2650; disengaging container liftingcolumn guide plate latches 2567 (FIG. 59I), which frees containerlifting column guide plate 2670 from its CLU third carriage 2550 workingmount, and which releases spring-loaded latch plates 2672(F) and2672(B), resulting in engagement of respective latch pins 2674(F) and2674(B) with respective latch holes 2656(F) (not shown) and 2656(B) incontainer lifting columns 2654, fixing vertical spatial relationshipbetween container lifting column guide plate 2670 and container liftingcolumn drive plate 2652; upwardly stroking CLU second carriage 2500,which elevates released container lifting column guide plate 2670 abovePAIDOC 2105 conveying surface; stroking CGU first 2150, second 2200, andthird 2250 carriages to align vertical centerlines of container gripperyokes 2306 with corresponding centerlines of CLU container liftingcolumn arrays 2653 with yokes 2306 below and contacting containerlifting column guide plate 2670; disengaging container lifting columndrive plate latches 2606, which frees container lifting column driveplate 2652 from its CLU fourth carriage 2600 working mount; CGU first2150 and second 2200 carriage maneuvering of CGU third carriage 2250into engagement with, lifting and maneuvering of CGAA 2300 and held CLAA2650 onto associated holding fixture 2680 situated on PAIDOC 2105 (FIG.59H); disengagement of latches 2265 fixing CGU third carriage 2250 toCGAA 2300(1), thereby releasing CGAA 2300(1) from CGU third carriage2250. CGU first 2150 and second 2200 carriages then maneuver CGU thirdcarriage 2250 into engagement with replacement CGAA 2300(2) (not shown)and install CGAA 2300(2) into CLU third 2550 and fourth 2600 carriagemounts by a process substantially the reverse of the disassembly processby which this point was reached.

On completion of CLAA replacement, CLU first carriage 2400 interactswith CLU conveyor element positioner 2353 to reposition each CLUconveyor element 2450 suitably for the upcoming production run. CLUfirst carriage 2400 moves each CLU conveyor element 2450 into CLUconveyor element positioner 2353, where clamp holding CLU conveyorelement 2450 to CLU first carriage 2400 is released and CLU firstcarriage 2400 is relocated relative to CLU conveyor element 2450.Programmable control system maintains a database of positions of CLUconveyor elements 2450 for each processed pallet type, thereby ensuringexecution of the repositioning process in the order necessary to avoidcollisions between CLU conveyor elements 2450.

Containerized Plant Spacing Conveyor (CPSC)

Adjoining and transitioning to CAIDOC 2107 is a containerized plantspacing conveyor (CPSC) 1660 (FIGS. 49, 52, 53, 54), which automaticallyadjusts spacing of arriving to-be-assembled containerized plants andtrays/flats of plants to match spacing of receptacles in correspondingpallets.

CPSC 1660 is divided into first and second servo-driven conveyor beltpositioning zones. Individually controllable adjoining zones and of CPSC1660 provides for substantially infinite adjustment ofcontainer-to-container spacing of containerized plants, as well as foradditional substantially infinite adjustment of much larger spacingbetween arrays of spaced containerized plants. This results in acorresponding time period for PAU 2100 to retrieve such arrays ofcontainerized plants from CAIDOC 2107 for assembly with pallets or toconvey away such an array of containerized plants from CAIDOC 2107,providing space to receive a new array to be disassembled from pallets.

Conveyor speeds in adjoining zone are matched as containerized plantscross transition, substantially averting container-to-belt slip, therebymaintaining high accuracy of containerized plant positioning in handlingby CPSC. Also, servo controls provide for programmable speed,acceleration and jerk, thereby further smoothing conveyor flow andaverting container-to-belt slip.

Pallet & Grid Rotating Unit (PGRU)

Following use, which may last for several months, pallets and grids willbe dirty and should be rinsed with water to maintain integrity ofsealing and reflective surfaces and to prevent debris from adverselyaffecting pallet and grid stack nesting for storage. Features of palletsand grids, such as water reservoirs and lips necessitate pallets bestood on edge for substantially complete drainage of rinse water.Further, it is preferable that standing on edge of pallets occursrepetitively, at a relatively high frequency, i.e., on a productionbasis, without manual interaction. Upon completion of pallet and gridrinsing, pallets should ideally be likewise returned to a workingposition. Automated pallet and grid rotator unit (PGRU) 5500 for suchpallet and grid manipulation.

Two PGRU's 5500(1) and 5500(2), which are capable of standing palletsand grids on edge as well as returning pallets and grids to theirworking orientations, are at infeed and outfeed ends of a pallet andgrid washing unit (PGWU) 5700 of FIGS. 60A, C, D, and E, forming a line.Ends of PGRU's opposite PGWU interface with interconnecting PC's. PGRU5500 is detailed in FIGS. 60G-N.

PGRU 5500(1) simultaneously rotates two pallets and grids as units fromworking orientation to “on edge” rinsing orientation. PGRU 5500(2) atopposite end of PGWU 5700 simultaneously rotates two pallets and gridsas units from “on edge” rinsing orientation to working orientation.

PGRU 5500 comprises two substantially identical carriage assemblies,movably attached to a common frame, that rotate and translatesymmetrically mirrored about a vertical plane centered on infeed PC andtangential to infeed PC flow direction.

PGRU 5500 comprises a frame 5502, plus, on each of two sides lateral toconveyor line, a horizontally, linearly translating first carriage5520(L/R), a reciprocally rotating and conveying second carriage5550(L/R), a conveying third carriage 5580(L/R), and a reciprocating andconveying fourth carriage 5620(L/R).

PGRU frame 5502 as illustrated, incorporates a linear track having rails5510 and 5511 9 not shown) and assembly first and second sync beltarrangements. First and second sync belt arrangements provide in partdescribed mirrored symmetrical motion of first carriages 5520(L) and5520(R), which traverse track 5510/5511. First synchronizing beltarrangement comprises sync belt sync sprocket 5503 and idler sprocket5505 and thereon mounted belt 5504 to which first carriages 5520(L) and5520(R) are coupled through clamps 5526(L) and 5526(R), respectively.Second synchronizing belt arrangement, comprising sync belt syncsprocket 5507 and idler sprocket 5509 and thereon mounted belt 5508 towhich first carriages 5520(L) and 5520(R) are coupled through clamps5528(L) and 5528(R), respectively. Sync shaft 5506, which providescarriage 1 synchronization redundancy, is coupled to sprockets 5503 and5507 and is supported near ends by bearings not shown. While two coupledsync belt arrangements are depicted, one arrangement, combined withcarriage 1 travel bumpers at ends of track 5510/5511 maintains firstcarriages 5520(L) and 5520(R) on track in the event of a belt break.Without the need for sync shaft 5506, relatively lesser expensive flator equivalent belts and pulleys can replace remaining sync belts andsprockets, respectively. Beneath PGWU frame 5502(1) as shown in FIG.60D, is a drip pan 5512 for catching accumulated irrigation waterspilled from pallet during rotation to an “on edge” orientation. Drippan 5512 funnels collected water to a discharge port that preferablydischarges into a culvert or underground piping which directs such waterto a retention pond. Such water is typically unacceptably contaminatedfor reuse in pallet rinsing.

Each PGRU first carriage 5520 is movably attached via linear bearings5521, 5522, 5523, and 5524 to PGRU frame 5502 track 5510/5511 andpivotally to respective second carriage 5550 via bearings 5529 and 5530.PGRU first carriage 5520 incorporates a PGRU second carriage rotationdrive servo gearmotor 5532 coupled to drive/sync shaft 5531, which iscoupled at each end to sync belt sprockets 5533 and 5534 and supportednear each end by proximal bearings not shown. An open-ended sync belt5536 fixed at a first end of a pulley segment 5552 of second carriage5550 wraps around sprocket 5533 and terminates at belt clip 5539 (notshown, complements belt clip 5540 shown). Belt clip 5539 couples syncbelt 5536 entering clip 5539 from one direction and two belts 5535laterally symmetrically spaced apart by width of belt 5536, enteringclip 5539 from direction opposite belt 5536. Laterally spaced belts 5535wrap around an idler sprocket 5541, straddle pulley segment 5552—wrappedbelt 5536, and wrap around pulley segment 5552 in opposite directionfrom belt 5536 and is fixed to end of pulley segment 5552 opposing belt5536 attachment end. A second open-ended sync belt 5538 fixed at a firstend of a pulley segment 5553 of second carriage 5550 wraps aroundsprocket 5534 and terminates at belt clip 5540. Belt clip 5540 couplessync belt 5538 entering clip 5540 from one direction and two belts 5537laterally symmetrically spaced apart by width of belt 5538, enteringclip 5540 from direction opposite belt 5538. Laterally spaced belts 5537wrap around an idler sprocket 5542, straddle pulley segment 5553—wrappedbelt 5538, and wrap around pulley segment 5553 in opposite directionfrom belt 5538 and is fixed to end of pulley segment 5553 opposing belt5538 attachment end. Servo gearmotor 5532 and described drive causesecond carriage 5550 to rotate about bearings 5529 and 5530, relative tofirst carriage 5520. Pivotal connection between PGRU second carriages5530(L) and 5530(R) necessitates that distance between PGRU first andsecond carriage pivotal joints 5529 and 5530 vary. First carriagebearings 5529 and 5530, running on PGRU track 5510/5511 provide for suchvariation.

PGRU second carriage 5550 incorporates: a first set of pins 5529 forpivotal attachment to PGRU first carriage 5520; pulley segments 5552 and5553 coupled to PGRU first carriage 5520 forming part of rotation drivedescribed above; an aligned pin and hole pair 5551 for pivotalconnection to a facing second carriage 5550; a servo gearmotor5558—driven positioning conveyor 5555; a track 5559/5560 for movableattachment of PGRU third carriage 5580; and a drive for positioning PGRUthird carriage 5580 relative to PGUR second carriage 5550. PGRU thirdcarriage 5580 positioning drive comprises gearmotor 5561 coupled todrive/sync shaft 5568, sync belt sprockets 5565 and 5569 attached toends of drive/sync shaft 5568, sync belt 5566 mounted to drive sprocket5565 and looping around idler sprocket 5567 mounted to front side ofPGRU second carriage 5550; and, sync belt 5570 mounted to drive sprocket5569 and looping around idler sprocket 5571 mounted to rear side of PGRUsecond carriage 5550. Track 5559/5560 is oriented to provide for motionof PGRU third carriage 5580 perpendicular to conveying surface of PGRUsecond carriage conveyor 5555.

PGRU third carriage 5580 incorporates: linear bearings 5581, 5582, 5583,and 5584, movably attaching PGRU third carriage 5580 to track 5559/5560of PGRU second carriage 5550; belt clamps 5586 and 5588 coupling PGRUthird carriage 5580 to associated drive belts 5566 and 5570; a servogearmotor 5592—driven positioning conveyor 5589; linear bearings 5593and 5594 movably attaching PGRU third carriage 5580 to track 5621/5624of PGRU fourth carriage 5620; a servo gearmotor drive for positioningPGRU fourth carriage 5620 relative to PGRU third carriage 5580. PGRUfourth carriage 5620 positioning drive comprises servo gearmotor 5595coupled to sync shaft 5600, near the front end of which is mounted syncbelt sprocket 5596 and idler rollers 5597 and 5598 which collectivelydrive open-ended sync belt 5599, and near the rear end of which ismounted sync belt sprocket 5601 and idler rollers 5598 and 5602 whichcollectively drive open-ended sync belt 5604. Sync belt 5599 is fastenedat its ends to ends of PGRU fourth carriage 5620 track front rail 5621.Sync belt 5604 is fastened at its ends to ends of PGRU fourth carriage5620 track rear rail 5624. Linear bearings 5593 and 5594 and associatedtrack 5621/5624 are oriented to provide for motion of PGRU fourthcarriage 5620 perpendicular to PC flow direction and tangential andproximal to conveying surface of PGRU third carriage conveyor 5589.

PGRU fourth carriage 5620 incorporates: track 5621/5624, movablyattached to linear bearings 5593 and 5594 of PGRU third carriage 5580;belt clamps 5622, 5623, 5625, and 5626, coupling PGRU fourth carriage5620 to associated drive belts 5601 and 5604; and, a servo gearmotor5629—driven positioning conveyor 5627.

Sequence of PGRU actions in rotation of pallets 502 (and, if applicable,nested grids 800) from “working” orientations to “on edge” orientationsis shown in FIGS. 60K-N in the same order. Prior to production run, PGRUthird carriages 5580 are automatically spaced a predefined distance fromPGRU second carriages 5550, resulting in minor clearance between tops ofpallets 502 (and, if applicable, nested grids 800) and conveyor surfacesof PGRU third carriage 5580. Such adjustment does not change over thecourse of a production run. As depicted in FIG. 60K, a pair of pallets502 (and, if applicable, nested grids 800) first index onto respectiveconveyors of PGRU second carriages 5550. As depicted in FIG. 60L, PGRUfourth carriages 5620 then advance toward pallets 502 a predefineddistance, placing conveying surfaces of PGRU fourth carriages 5620 inclose proximity to outer edges of subject pallets 502 to avertuncontrolled movement of pallets 502 during upcoming rotation maneuver.As depicted in FIG. 60M, PGRU second carriages 5550 then together rotatethrough 90 degrees about their common pivotal axis 5551 and PGRUfirst/second such that their common pivotal axis 5551 rises verticallyand PGRU first carriages 5520(1) and 5520(2) and associated PGRUfirst/second carriage pivot joints 5530(1) and 5530(2) approach oneanother. As depicted in FIG. 60N, PGRU fourth carriages 5620 thenretracts downward to same elevation as adjoining outfeed conveyor, whichhas guides to support “on edge” orientation of pallets 502 (and, ifapplicable, nested grids 800) now being conveyed. Finally, PGRU 5500returns to its original orientation to receive another pair of pallets502 (and, if applicable, nested grids 800).

Sequence of PGRU actions in rotation of pallets 502 (and, if applicable,nested grids 800) from “on edge” orientations to “working” orientationsis the reverse of that described above.

Pallet & Grid Washing Unit (PGWU)

Pallet and grid washing unit (PGWU) 5700 provides for rinsing of palletsand grids having been exposed for several months to splashedcontainerized plant soil, fertilizer and dust. As stated above and asdepicted in FIGS. 60A, C, D and E, PGWU 5700 is between and functionallyaligned with two PGRU's 5500(1) and 5500(2) as PGWU processes pallets(and, if applicable, thereon nested grids) which are standing “on edge”.

PGWU main conveyor 5720 aligns with PGRU second carriage conveyors 5555and upwardly supports pallets processed by or bypassing PGWU 5500. Inorder to accommodate a PGWU bypass mode, PGWU main conveyor 5720 is ofsufficient width to convey a pair of pallets spaced closely laterally onconveyor. PGWU main conveyor 5720 runs continuously, generally at aconstant speed, which is adjustable depending on PGWU 5500 operatingmode. Beneath PGWU main conveyor 5720 is a drip pan 5721 having tworinse water collection sections. First rinse water collection section isupstream—relative to PGWU main conveyor 5720—from second rinse watercollection section, and is separated from second rinse water collectionsection by drip pan separation wall 5722. First rinse water collectionsection receives spilled rinse water from a pallet and grid low-pressureinitial rinse area and a pallet and grid high-pressure rinse area.Resulting rinse water, considered unacceptably contaminated for reuse,is discharged into a culvert or underground piping that directs suchwater to a retention pond. Second rinse water collection sectionreceives spilled rinse water from a pallet and grid low-pressure finalrinse area. Resulting rinse water, considered to be suitably clean forreuse, is discharged to the inlet 5727 piping of recirculation pump5723, which, in turn, pumps such rinse water through piping 5724 andflexible 5725 to pallet and grid low-pressure initial rinse waterdistribution system 5785 to be combined with clean PGWU 5700 supplywater.

PGWU stationary frame 5740 incorporates PGWU first carriage verticalguide rails 5766, 5767, 5768, and 5769 and an automatic, cable-based,carriage elevating suspension system, which supports PGWU first carriage5800 substantially above PGWU main conveyor 5720. Automatic suspensionsystem comprises: automatic motorized elevator drive 5741 with failsafebrake, cable winding drums 5745 and 5746 (not shown), sync shaft 5744;sync shaft bearings 5742 and 5743, support cables 5747, 5748, 5749, and5750; pulley blocks 5751, 5752, 5753 (not shown), and 5754; and, heightlimit switches. Suspension system is immobile during a given productionrun. Suspension system raises PGWU first carriage 5760 and all thereonmounted components to produce substantial clearance between bottoms ofcomponents mounted to PGWU first carriage 5760 and conveying surface ofPGWU main conveyor 5720, thereby achieving a PGWU bypass mode in whichrelatively tall stacks of pallets may pass freely through PGWU on PGWUmain conveyor 5720. Alternately, motorized, sync belt-synchronized acmescrews could replace cables, being situated reasonably proximal to(former) cable vertical runs.

PGWU first carriage 5760 incorporates: linear bearings 5762, 5763, 5764,and 5765, movably attaching PGWU first carriage 5760 to PGWU stationaryframe 5740; a low- and high-pressure water pump unit 5785, water spraynozzle arrays and associated distribution manifolds, (mirrors of suchnozzle arrays and manifolds described below); an air drying blower unit5786, drying air nozzle array and associated distribution manifold(mirrors of such nozzle array and manifold described below); mirrored“on edge” pallet fences 5782 and 5784 which make up parts of mirroredpallet tracks 5826 and 5876, respectively, running the length of PGWU5700; mirrored lateral rails 5766, 5767, 5768, and 5769 to which PGWUsecond carriages 5800 and 5850 are movably attached; and, an automaticgearmotor/sync belt-actuated PGWU second carriage lateral translationdrive. Electric motor-driven low-pressure water pumps are of thecentrifugal variety due to their ability to tolerate contamination inthe pumped water. Electric motor-driven high-pressure water pumps are ofthe positive displacement variety to achieve relatively high pumpingefficiency. Due to close pumping element tolerances, single-pass inletfiltration is employed. Supply water pressure, produced by well orreservoir pumps or elevated tanks, is suitable for low-pressure rinsesdescribed, and for charging inlets of high-pressure pumps. PGWU secondcarriage lateral drive comprises a gearmotor 5770, attached sync beltsprocket 5771, sync belt 5772, sync belt sprocket 5773, front leftdrive/sync sprocket 5774, front drive/sync belt 5775, front idlersprocket 5776, front-back sync shaft 5777 attached to drive/syncsprockets 5774 and 5778, rear left drive/sync sprocket 5778, reardrive/sync belt 5779, rear idler sprocket 5780. PGWU second carriagelateral drive provides for drive and synchronization of front and rearends of PGWU second carriages 5800 and 5850. Alternately, motorized,sync belt-synchronized screws would also work well for synchronizationof PGWU second carriages 5800 and 5850.

PGWU left-hand-side second carriage 5800 incorporates: beam 5801supporting most components; linear bearings 5802, 5803, 5804, and 5805,movably attaching PGWU left-hand-side second carriage 5800 to lateralrails 5766 and 5767 of PGWU first carriage 5760; clamps 5807 and 5809,coupling PGWU left-hand-side second carriage 5800 to associated drivebelts 5775 and 5779; left-hand-side, servo-driven, “on-edge” palletconveyor; initial low-pressure rinse water spray nozzle array 5823 anddistribution manifold; high-pressure water pump unit 5810 and associatedwater spray nozzle array 5824 and distribution manifold; finallow-pressure rinse water spray nozzle array 5825 and distributionmanifold; and, drying air nozzle array 5831 and distribution manifold.Conveyor comprises: servo positioning conveyor drive gearmotor 5811;upper sync belt drive sprocket 5812; upper sync belt 5813, upper syncbelt idler sprocket 5818; upper-lower conveyor drive sprocket sync shaft5832; lower sync belt drive sprocket 5814; lower sync belt 5815; lowersync belt idler sprocket 5819; flight upper track 5816; flight lowertrack 5817; and, flight 5820. Conveyor flights 5820 provide positive,constant drive of pallets (and, if incorporated, nested grids) pastspray nozzle arrays that can readily disturb conveying workpieces.

PGWU right-hand-side second carriage 5850 incorporates: beam 5851supporting most components; linear bearings 5852, 5853, 5854, and 5855,movably attaching PGWU right-hand-side second carriage 5850 to lateralrails 5768 and 57697 of PGWU first carriage 5760; clamps 5857 and 5859,coupling PGWU right-hand-side second carriage 5850 to associated drivebelts 5775 and 5779; right-hand-side, servo-driven, “on-edge” palletconveyor; initial low-pressure rinse water spray nozzle array 5873 anddistribution manifold; high-pressure water pump unit 5860 and associatedwater spray nozzle array 5874 and distribution manifold; finallow-pressure rinse water spray nozzle array 5875 and distributionmanifold; and, drying air nozzle array 5881 and distribution manifold.Conveyor comprises: servo positioning conveyor drive gearmotor 5861;upper sync belt drive sprocket 5862; upper sync belt 5863, upper syncbelt idler sprocket 5868; upper-lower conveyor drive sprocket sync shaft5882; lower sync belt drive sprocket 5864; lower sync belt 5865; lowersync belt idler sprocket 5869; flight upper track 5866; flight lowertrack 5867; and, flight 5870.

FIG. 60F illustrates the PGWU left-hand-side “on edge” pallet conveyor,with arrays 5823, 5824, 5825, and 5831 of spray nozzles and air driernozzles, which are mirrored on associated left-hand-side track fence5782. PGWU main conveyor 5720, PGWU left-hand-side second carriage 5800“on edge” conveyor, and left-hand-side track fence 5782 collectivelyform a PGWU left-hand-side “on edge” pallet track 5826 (FIGS. 60A, B)which pallets (and, if incorporated, nested grids) follow through PGWU5700. This combination of components is mirrored about a vertical planecentered on PGWU main conveyor 5720 and tangential to PGWU main conveyor5720 flow directions. Normal distance between each “on edge” conveyorand the corresponding fence is automatically adjusted ahead of aproduction run via positioning gearmotor 5770, setting it based itsposition as measured by a PGWU second carriage drive train shaft encoderor carriage-connected linear encoder or distance transducer, and oncontrol system database storing (among other dimensions) pallet height,pallet-grid nesting height (if grids are incorporated), plus a minorclearance figure, which are summed together to define the appropriategap for reliably conveying the subject pallets (and, if incorporated,nested grids).

Initial low-pressure rinse nozzle linear arrays, typical of nozzle array5823 shown in FIG. 60F, are downwardly sloped in PGWU conveyor workingflow direction to cause accumulation of rinse water on portions ofpallets struck by lower-elevation initial low-pressure rinse nozzle jetsas pallets are conveyed past, aiding loose debris removal by initiallow-pressure rinsing action. High-pressure rinse nozzle linear arrays,typical of nozzle array 5824 shown in FIG. 60F, are vertical to presentpallet walls having minimal accumulation of rinse water on portions ofpallets struck by all high-pressure rinse nozzle jets as pallets areconveyed past, best ensuring high-pressure rinse nozzle jetssubstantially directly impact pallet (and, if applicable, nested grid)walls with insignificant attenuation by pallet-laden residual rinsewater, thereby maximizing effectiveness of pallet high-pressure rinsingoperation. Vertical arrays of high-pressure rinse water nozzles alsogenerally correspond with vertical leading and trailing edges of pallets(and, if incorporated, nested grids) being conveyed, promoting the useof rinse water-saving valves and associated limit switches or palletposition measuring devices or control system-generated timing thatprovides for stopping of rinsing action, particularly energy intensivehigh-pressure rinsing, in the absence of pallets (and, if incorporated,nested grids) being rinsed.

Pallet & Grid Stacking/Destacking Unit (PGSU) Embodiment 1

As shown in FIGS. 61A-S, PGSU 4500 in a first embodiment of theinvention, operates in concert with associated PC's to stack and destackpallets 302, 402, or 502 and, as required, grids 600 or 800 (402, 502,and 600 shown) as dictated by PAS operating mode.

PGSU 4500 comprises framework 4510 supporting a PGSU first carriage 4550and nested second 4600 and third 4700 carriages above PGSU positioningPC 4512. Frame 4510 incorporates a linear, horizontal first track4514—perpendicular to PGSU PC 4512 flow directions—for movableattachment of PGSU first carriage 4550. Also mounted on frame 4510 is: aservo gearmotor 4515; with mounted sync belt sprocket 4516; thereonmounted sync belt 4517; sync/drive shaft drive sprocket 4518; drive/syncshaft 4525 with drive/sync sprockets 4519 and 4520 proximal to its endsand mounted to frame 4510 on bearings not shown; PGSU first drive/syncbelt 4521 mounted to drive/sync sprocket 4519 and frame 4510—mountedidler sprocket 4523; PGSU second drive/sync belt 4522 mounted todrive/sync sprocket 4520 and frame 4510—mounted idler sprocket 4524.Described arrangement, drives first carriage 4550 reciprocally alongfirst track 4514. First carriage 4550 provides for accurate positioningin shuttling of second 4600 and third 4700 carriages laterally acrossPGSU PC 4512 so that pallets and, if applicable, grids may be picked upfrom or deposited to both sides of PGSU PC 4514.

Mounted to first carriage 4550 is a first set of linear (or camfollower) bearings 4560, which provide for movable attachment of firstcarriage 4550 to first track 4551 of frame 4510. Also mounted to firstcarriage 4550 are two vertical linear bearing arrangements 4560 and4570, each for movable attachment of second 4600 and third 4700carriages via linear tracks 4601 and 4701 mounted to second 4600 andthird 4700 carriages, respectively. Mounted to first carriage 4550 is aservo gearmotor 4561 with thereon mounted sync belt sprocket 4562,flanked by two idler rollers 4563 that provide for requisitebelt-sprocket contact angle between sprocket 4562 and open-ended,vertical drive sync belt driving 4605 PGSU second carriage 4600. Alsomounted to first carriage 4550 is a servo gearmotor 4571 with thereonmounted sync belt sprocket 4572, flanked by two idler rollers 4573 thatprovide for requisite belt-sprocket contact angle between sprocket 4572and open-ended, vertical drive sync belt 4705 driving PGSU secondcarriage 4700. Also mounted between first carriage 4550 and each ofsecond 4600 and third 4700 carriages is a failsafe brake for emergencyand idle fixing of respective carriage relative to first carriage 4550,and a “counterbalance” pneumatic cylinder as described above.

Vertical drive arrangement for each of second 4600 and third 4700carriages alternately could comprise a closed sync belt mounted to adrive sprocket and idler sprocket at opposing ends of respectivecarriage riser member, having a point on one belt run clamped to firstcarriage, wherein driving servo gearmotor is mounted to subject secondor third carriage and is coupled to subject drive sprocket, therebyeliminating reverse flexing of drive belt, improving its longevity.Vertical drives could alternately also by hydraulic or pneumaticservo-based, or an electric servo with cable/drum-based motiontransmission.

As detailed in FIGS. 61B and C, each of second 4600 and third 4700carriages are substantially identical, with the potential exception ofpallet adapter attachments. Each of second 4600 and third 4700 carriagescomprises a slender vertical member 4602 along which respective track4601 is attached. At bottom of vertical member 4602 is attached agenerally horizontal, planar pallet gripper head upper base plate 4620having vertically downwardly extending pilot pins 4621 and 4622, thefree edges of which are tapered to facilitate engagement withcorresponding holes 4661 and 4662 through a pallet gripper head lowerbase plate 4660 and two pallet gripper adapter plates 3110 and 3140. Apositioning servo gearmotor 4623, which is rigidly attached to palletgripper head upper base plate 4620 upper surface along one edge drives async shaft 4624, the two ends of which are coupled to two mirrored bellcranks 4627 and 4628. Bell cranks 4627 and 4628 are, in turn, pivotallypinned in an axis parallel to and spaced generally horizontally fromsync shaft 4624 to the upper ends of vertical links 4633 and 4634 (notshown). Bell cranks 4627 and 4628 are further pinned in an axis parallelto sync shaft 4624 and spaced generally vertically from sync shaft 4624axis and to first ends of horizontal links 4629 and 4630. Second ends ofhorizontal links 4629 and 4630 are pinned at identical locations on twoadditional identical mirrored bell cranks 4631 and 4632, respectively,that rotate about fixed axis pinned joints that are spaced horizontallyfrom sync shaft 4624 substantially orthogonally across upper base plate4620. Identically to arrangement of first set of bell cranks 4627 and4628, bell cranks 4631 and 4632 are also pinned to the upper ends of twoadditional generally vertical links 4635 and 4636, respectively. Lowerends of vertical links 4633, 4634, 4635, and 4636 are pinned tocorresponding pivot points on lower base plate 4660. Spacing betweenvertical link lower pivotal joints matches spacing between vertical linkupper pivotal joints, resulting in parallelism between vertical linksand between upper 4620 and lower 4660 base plates. This arrangementprovides for minor vertical normal reciprocal programmable stroking ofpallet gripper head lower base plate 4660 relative to upper base plate4620, while maintaining parallelism between upper 4620 and lower 4660base plates at four support joints.

Hanging over the edge proximal to each of four corners of upper surfaceof upper base plate 4620 is a spring-applied, pneumatically releasedhook 4637. Hook 4637 incorporates a horizontal slide portion 4638, ariser portion extending downwardly from slide portion, a flange portion4639 extending inward at the lower end of riser portion, and a lip 4640protruding upwardly and outwardly from upper, inner edge of flangeportion 4639. Hanging over the edge proximal to each of four corners ofupper surface of lower base plate 4660 is a spring-applied,pneumatically released hook 4663. Hook 4663 incorporates a horizontalslide portion 4664, a riser portion extending downwardly from slideportion, a flange portion 4665 extending inward at the lower end ofriser portion, and a lip 4666 protruding upwardly and outwardly fromupper, inner edge of flange portion 4665.

Pallet gripper upper adapter plate 3110 rests on flanges 4639 ofrespective hooks 4637 mounted to upper base plate 4620, with respectivespring-retracted hook drive pneumatic cylinders 4641 disengaged. Hookflange lips 4640 and complementary adapter plate 3110 support surfacesare shaped to prevent inadvertent actuation, i.e., release, of hooks4637 and adapter plate 3110 while weight of adapter plate 3110 is stillborne by hooks 4637. Similarly, pallet gripper lower adapter plate 3140rests on flanges 4665 of respective hooks 4663 mounted to lower baseplate 4660, with respective spring-retracted hook drive pneumaticcylinders 4667 disengaged. Hook flange lips 4666 and complementaryadapter plate 3140 support surfaces are shaped to prevent inadvertentactuation, i.e., release, of hooks 4663 and adapter plate 3140 whileweight of adapter plate 3140 is still borne by hooks 4663.

Pallet gripper upper 4620 and lower 4660 base plates further eachincorporates a mechanism for actuating pallet hooking finger 3122 and3132 array mounting/drive plates 3120 and 3130, respectively. Mounted toupper base plate is a vertical pivotal shaft 4643 that extends downwardfrom an input crank 4644 above the upper base plate 4620 through abearing 4645, to a lower end having a pair of opposing cams 4647straddling shaft 4643. Pneumatic cylinder 4646, pinned at one end to abracket fastened to upper base plate 4620 reciprocally drives crank4644, thereby reciprocally rotating shaft 4643. Opposing cams 4647 onthe lower end of shaft 4643 engage drive slots 3121 and 3131 of twopallet hooking finger mounting/drive plates 3120 and 3130, respectively.Pallet hooking finger mounting/drive plates 3121 and 3131 are supportedby pallet gripper upper adapter plate 3110 and guided to slidehorizontally parallel to each other. Minor rotation of shaft 4643 causescams 4647 to push on walls of slots 3121 and 3131 of pallet hookingfinger mounting/drive plates 3120 and 3130, respectively, in opposingdirections. Mounted to and extending downward from pallet hooking fingermounting/drive plates 3120 and 3130 are pallet hooking fingers 3122 and3132, respectively, which, assembled together, form a two-dimensionalarray of pallet hooking finger pairs that in plan match the arrangementof pallet container receptacles of an associated pallet configuration.

Lower ends of pallet hooking fingers 3122 and 3132 incorporate flanges3154 and 3155 that face away from like flanges on opposingpallet-hooking fingers. Opposing fingers 3122 and 3132, on being loweredso as to protrude down through container lifting access/pallet liftingholes 545/603/815, move apart to engage pallet/grid walls adjoiningcontainer lifting access/pallet lifting holes 545/603/815 ondeactivation of pneumatic cylinder 4646—a failsafe condition. Opposingfingers 3122 and 3132, move toward one another to disengage pallet/gridwalls adjoining container lifting access/pallet lifting holes545/603/815 on activation of pneumatic cylinder 4646.

Pallet hooking finger drive/mounting plates 3150 and 3160 and theretomounted pallet hooking fingers 3152 and 3162, respectively, which areassociated with pallet gripper lower base 4660 and adapter 3140 plates,operate similarly to their counterparts associated with pallet gripperupper base 4260 and adapter 3110 plates. However, directions of movementand locations of pallet hooking finger mounting plates 3150 and 3160 andcorresponding fingers 3152 and 3162, respectively, align with differentpairs of container lifting access holes 545/603/815 through pallets andgrids.

Vertically movably attached to and normally hanging below pallet gripperlower adapter plate 3140 is a pallet/grid guide plate 3180 havingdownwardly tapering features that complement those of the pallet or gridto be gripped. Pallet/grid guide plate 3180 facilitates alignmentbetween pallet gripper head and pallet or grid, as applicable.Pallet/grid guide plate 3180 further incorporates a sensors that,together with carriage vertical position measurement derivable from thesecond 4600 or third 4700 carriage vertical drive servo system, signalthe PGSU 4500 controls that the pallet/grid guide plate 3180 is beingsupported by a stack and no longer by the pallet gripper lower adapterplate 3140, indicating the top of a stack (or, if at a predefinedelevation, an absent stack) has been located.

Arrangement of two groupings of pallet gripper fingers, the verticalseparation between which servo positioning drive 4623 automaticallyadjusts, provides for forced separation of one pallet (or grid, asapplicable) from the top of a stack of same, such stack sitting on PC4512 below PGSU 4500, or from the bottom of a stack accumulated on thepallet gripper adapter assembly 4600 or 4700, as applicable.

Pallet gripper adapter assembly 3100 of a given configuration hasgeometry that complements the geometry of key features of a pallet orgrid to be gripped and, thus adapt PGSU 4500 for handling a givenconfiguration of pallet and/or grid. Shown in FIGS. 61B and C is apallet gripper assembly 4600 or 4700 with a pallet gripper adapterassembly 3100 for gripping a pallet having four rows (staggered) of fourspaced hexagonal segments.

Operation of pallet gripper fingers in de-stacking process is depictedin sections FIGS. 61D-K, showing relationships between fingers 3122,3132, 3152 and 3162 and respective pallet container liftingaccess/pallet lifting holes 545A, 545B, 545C, and 545D. Figures furtherdepict a partial pallet stack held by pallet fingers. Duringde-stacking, pallet holding fingers 3122 and 3132 remain fixedvertically relative to pallet drive fingers 3152 and 3162, the verticalmotion of which is servo actuated by pallet gripper assembly moving baseplate 4660 (FIGS. 61B, C). In a “home” position, shown in FIG. 61D,flanges 3154 and 3164 of respective pallet drive fingers 3152 and 3162engage walls 559(1C) and 559(1D) of bottommost pallet 502(1), andflanges 3124 and 3134 of respective pallet holding fingers 3122 and 3132engaged walls 559(1A) and 559(1B) of second bottommost pallet 502(2). Asshown in FIG. 61E, pallet drive fingers 3152 and 3162 then strokedownward while engaging bottommost pallet 502(1), forcing bottommostpallet 502(1), if necessary, apart from second bottommost pallet 502(2)(and, thus, remainder of partial stack) still held in original positionby engaged pallet holding fingers 3122 and 3132. As shown in FIG. 61F,pallet drive fingers 3152 and 3162 then horizontally retract intorespective container lifting access/pallet lifting holes 545(C) and545(D), disengaging walls 559(C) and 559(D), releasing bottommost pallet502(1). As shown in FIG. 61G, pallet drive fingers 3152 and 3162 thenstroke upward until elevation of their respective flanges 3154 and 3164substantially matches (or is slightly lower than) elevation of flanges3124 and 3134 of respective pallet holding fingers 3122 and 3132,thereby rendering them properly situated for engagement of pallet drivehooks 3152 and 3162 with walls 559(C) and 559(D) of pallet 502(2). Asshown in FIG. 61H, pallet drive fingers 3152 and 3162 then horizontallyadvance, engaging walls 559(2C) and 559(2D), gripping new bottommostpallet 502(2). As shown in FIG. 61I, pallet holding fingers 3122 and3132 then horizontally retract into respective container liftingaccess/pallet lifting holes 545(A) and 545(B), disengaging walls 559(A)and 559(B), enabling pallet drive fingers 3152 and 3162 to controlvertical positioning of new bottommost pallet 502(2). As shown in FIG.61J, pallet drive fingers 3152 and 3162 then stroke downward to “home”position while engaging new bottommost pallet 502(2), lowering remainderof partial stack formerly held in original position by engaged palletholding fingers 3122 and 3132. As shown in FIG. 61K, pallet holdingfingers 3122 and 3132 then horizontally advance, engaging walls 559(3A)and 559(3B), gripping new second bottommost pallet 502(3). Thiscompletes one pallet singulation cycle, forming a portion of a completepallet (and, if applicable, grid) de-stacking cycle. This portion of apallet (and, if applicable, grid) de-stacking process is alsoreversible, yielding a complementary portion of a pallet stackingprocess.

As can be seen in FIGS. 61L-S, during stacking, partial stacks ofpallets and, if applicable, grids, accumulate on respective pallet/gridgripper assemblies 4600/4700. This is accomplished by repeated sequenceof: infeed 4513 and PGSU 4512 PC indexing of a pair of laterally closelyspaced pallets and, if applicable, grids nested thereon to belowrespective pallet/grid gripper assemblies 4600/4700 (FIG. 61L); palletgripper assembly 4700 picking up of a pallet and, if applicable, palletgripper assembly 4600 picking up of a grid, from a first side ofconveyor 4512 (FIG. 61M, N); shuttling of pallet/grid gripper assemblies4600/4700 to above second side of conveyor 4512 (FIG. 61P); palletgripper assembly 4700 picking up of a pallet and, if applicable, palletgripper assembly 4600 picking up of a grid, from second side of conveyor4512 (FIG. 61Q, R); infeed 4513 and PGSU 4512 PC indexing of anotherpair of laterally closely spaced pallets 502 and, if applicable, grids600 to below respective pallet/grid gripper assemblies 4600/4700 (FIG.61S); pallet gripper assembly 4700 picking up of a pallet and, ifapplicable, pallet gripper assembly 4600 picking up of a grid, from asecond side of conveyor 4512; shuttling of pallet/grid gripperassemblies 4600/4700 to above first side of conveyor 4512; and, palletgripper assembly 4700 picking up of a pallet and, if applicable, palletgripper assembly 4600 picking up of a grid, from first side of conveyor4512 (similar to FIGS. 61M, N). This portion of the pallet (and, ifapplicable, grid) stacking process is also reversible, yielding acomplementary portion of a pallet de-stacking process.

Integration of controls of PGWU 4500 and associated PC's 4511, 4512 and4513 provide for iterative pallet 502, and, if applicable, grid 600,stacking and de-stacking. In stacking mode, on control systemanticipation of pallet/grid gripper assemblies 4600/4700 reachingcapacity of held partial stacks of pallets 502 and, if applicable, grids600, infeed PC 4513 temporarily discontinues feeding pallets 502 and, ifapplicable, grids 600, in order for pallet/grid gripper assemblies4600/4700 to remove remaining pallets 502 and, if applicable, grids 600from PGSU PC 4512. Once PGSU PC 4512 is deplete, PC 4511, which adjoinsPGSU PC 4512, and which participates in stacking and de-stacking ofpallets 502 and, if applicable, grids 600, along with PGSU PC 4512,indexes its partial stacks (if present) to beneath pallet/grid gripperassemblies 4600/4700, which, in turn, deposit PGSU-held partial stacksonto PC 4511—supplied partial stacks (if present) below. PC's 4511 and4512 then index accumulated stacks back onto PC 4511 if not complete, orbeyond PC 4511 to storage, if complete, and stacking sequence resumeswith pallet/grid input from PC 4513. This portion of pallet (and, ifapplicable, grid) stacking is also reversible, yielding a complementaryportion of a pallet de-stacking process.

Pallet & Grid Stack Accumulator (PGSA)

PGSA 3500 in a first embodiment comprises a pallet & grid storageconveyor array 3550 comprising several (four shown) equal-lengthhorizontal servo-driven positioning PC's 3552, 3553, 3554, and 3555spaced normally, vertically relative to one another and supported by acommon frame. At each end of the PGSA storage conveyor array 3550 is apallet & grid stack elevator (PGSE) 3510(1) and 3510(2) with an integralservo-driven positioning PC 3540(1) and 3540(2), respectively. PGSA 3500temporarily stores stacks of pallets and grids of a first configurationproduced on a substantially ongoing basis by a disassembly process. PGSA3500 also dispenses stored stacks of pallets and grids of a differentconfiguration required for a substantially ongoing assembly process.Having two PGSE's 3510(1) and 3510(2), PGSA 3500 can substantiallysimultaneously store and dispense pallets and grids to accommodate onePAU1 2100(1) in disassembly mode and a second PAU2 2100(2) in assemblymode.

PGSA 3500 stores pallet & grid adapters tools not in production at agiven time. Further, PGSA 3500 receives, stages and dispenses such itemsas dictated by production schedule and tool handling algorithmsmaintained by control system, thereby facilitating automatic systemconfiguration changes. Incorporation of at least two levels in PC array3550 and two PGSE's 3510(1) and/or 3510(2) yields a carousel arrangementthat provides stored item manipulation resulting in unrestrained accessto any adapter tool.

Control system maintains geometry of pallets, grids, tools, PGSA 3500,as well as real-time operating status and can, therefore anticipate PGSA3500 depletion and filling to capacity. On anticipated PGSA 3500depletion of a pallet/grid stack supply, control system calls fortransferal of a PATT 1200 ‘load’ of pallet and grid stacks drawn from a‘permanent’ designated field storage area to the PGSA 3500. PACTU 5000,transfers stacks of pallets and grids from PATT 1200 to PAS 2000 PC'sfor conveying to PGSA 3500 via PGSE's 3510(1) and/or 3510(2).

On anticipated PGSA 3500 filling to capacity of a pallet/grid stacksupply, control system calls for transferal of a PATT 1200 ‘load’ ofpallet and grid stacks drawn from the PGSA 3500 to a ‘permanent’designated field storage area. PAS 2000 PC's convey pallet and gridstacks from PGSA 3500 via PGSE's 3510(1) and/or 3510(2) to PACTU 5000,which transfers pallet and grid stacks from PAS 2000 PC's to PATT 1200for transport to field-designated storage area.

PGSE's 3510(1) and 3510(2) service PGSA 3500 by transferring pallet andgrid stacks between various PGSA PC 3552, 3553, 3554, and 3555elevations and elevation of PC's with which PGSA 3500 interfaces.

Pallet Crossover Conveyor (PXC)

The first embodiment of PAS 2000 incorporates primarily two parallellines of PC's, designated (A) and (B) where necessary in FIGS. 49-54,having interspersed equipment and having three interconnecting palletcrossover conveyors (PXC's). A first PXC, extends between thestack-handling side of first PGSU 4500(1) and PGSA 3500 comprises twolateral switch conveyors 2004(A1) and 2004(B1) and one lateral flowconveyor 2005(1) between switch conveyors 2004(A1) and 2004(B1). Asecond PXC, extends from between PAU 2100(1) and first PGRU 5500(1) tobetween PAU 2100(2) and second end of PGSA 3500, and comprises twolateral switch conveyors 2004(A2) and 2004(B2) and one lateral flowconveyor 2005(2) between switch conveyors 2004(A2) and 2004(B2). A thirdPXC, extends from PACTU 5000 PAU 2100(2), and comprises two lateralswitch conveyors 2004(A3) and 2004(B3) and three lateral flow conveyors2005(A3), 2005(C3) and 2005(B3) (in stated order) between switchconveyors 2004(A2) and 2004(B2).

Each switch conveyor, comprises an electric motor-driven cam,pneumatically, or comparably actuated lift table on which is mounted aroller conveyor having conveyor rollers interleaved with sync belt loopsof a laterally flowing composite sync belt conveyor that is mounted tothe frame forming the base of lift table.

In its lowered position, lift table supports rollers of the switchconveyor with the uppermost surface of each roller slightly below uppersurface of the upper run of each sync belt forming switch conveyor. Inits raised position, lift table supports rollers of the switch conveyorwith the uppermost surface of each roller slightly above upper surfaceof the upper run of each sync belt forming the switch conveyor.

Conveyor loops, formed through incorporation of PXC's, enable PAS toretrieve PA's from a PATT, perform multiple functions on the plantmaterial in those PA's, and return subject plant material, potentiallyin differently configured PA's, to potentially the same PATT from whichit was retrieved, in a continuous manner.

First PXC 2004(A1)-2005(1)-2004(B1) provides a PC link as stated,though, through programmable controls of system, provides for lateralshifting of items on line (A) or (B). Either switch PC 2004(A1) or2004(B1) can also be used for PAS loading and unloading of a PAS adaptertool having been serviced or about to be services, respectively.

Second PXC 2004(A2)-2005(2)-2004(B2) primarily provides for feeding ofPGWU 5700 from both PAU's 2100(1,2) operating in disassembly mode, as inthe case of plant material shipping. Second PXC2004(A2)-2005(2)-2004(B2) can also provide for feeding from PGSA of bothPAU's 2100(1,2) operating in assembly mode, as in the case of plantmaterial receiving or potting, particularly while PGWU 5700 is beingserviced. Also, second PXC 2004(A2)-2005(2)-2004(B2) forms part of a PCloop for the processing of PA's as whole units (i.e., involving nodisassembly). In this case, PACTU 5000 retrieves PA's from PATT 1200 andplaces them on PC 5001, from which PA's flow through first PAU 2100(1)untouched, then across second PXC 2004(A2)-2005(2)-2004(B2) then throughsecond PAU 2100(2) untouched, then along PC 2003(B3), then across thirdPXC 2004(B3)-2005(B3)-2005(C3)-2005(A3)-2004(A3) (or an alternateparallel path), then along PC 2003(A3) to PC 5002, from which PACTU 5000retrieves it and returns it to PATT 1200.

Third PXC 2004(B3)-2005(B3)-2005(C3)-2005(A3)-2004(A3), together withadditional, like-constructed parallel PXC's2004(B4)-2005(B4)-2005(C4)-2005(A4)-2004(A4), etc., with respectiveconnecting PC's 2003(B4), 2003(A4), etc., form a semi-automatic weedingarea. PC's 2005(C3), 2005(C4), etc., are each slow-, constant-speed PC'salong the two sides of which are stationed weeding workers who hand weedplant material in PXC-borne PA's. Lateral conveyor portions of switchPC's 2004(B3), 2004(B4), etc, as well as lateral PC's 2005(B3),2005(B4), etc. are servo positioning. With more than one weeding areaPXC operating, PC 2003(B3) accumulates the number of PA's matching thenumber of weeding area PXC's operating, up to the maximum number ofweeding area PXC's incorporated into PAS (4 shown). Number of PXC'soperating in weeding area is extrapolated from the average amount oftime necessary for one weeding worker to weed one containerized plantpalletized and flowing along a given PXC as described, and the requiredproduction throughput established by nursery management, up to the PASoperational limit.

Once switch PC's 2004(B3), 2004(B4), etc. are clear of prior-conveyedPA's, PC's 2003(B3)-2004(B3)-2003(B4)-2004(B4), etc., quickly distributeto the active switch PC's 2004(B3), 2004(B4), etc. pairs of PC2003(B3)-accumulated PA's. Once trailing edges of preceding PA pairshave crossed respective transitions between lateral PC's 2005(B3) and2005(C3), 2005(B4) and 2005(C4), etc., switch PC's 2004(B3), 2004(B4),etc., simultaneously switch directions and PA's on respective switchPC's 2004(B3), 2004(B4), etc., are quickly conveyed along respectivePXC's to close gaps between their respective leading edges and thepreceding PA's trailing edges. Upon closure of subject gaps, speed oflateral PC portion of each switch PC 2004(B3), 2004(B4), etc. and ofrespective lateral PC 2005(B3), 2005(B4), etc. matches that of lateralPC 2005(C3), 2005(C4), etc. Thus, a continuous slow-speed flow ofpalletized plant material is conveyed past weeding workers.

Once trailing edges of preceding PA pairs have crossed respectivetransitions between lateral PC's 2005(C3) and 2005(A3), 2005(C4) and2005(A4), etc., preceding PA pairs are quickly conveyed along respectivePXC's, onto switch PC's 2004(A3), 2004(A4), etc., opening gaps betweentheir respective trailing edges and the succeeding PA's leading edges.This provides time for switch PC's 2004(A3), 2004(A4), etc. tosimultaneously switch directions and quickly convey switch PC-borne PApairs to PC's 2003(A3) and 5002, where they accumulate in staging fortransfer to PATT 1200 by PACTU 5000.

Below weeding area PXC's are conventional belt conveyors 2012 and 2014for collecting pulled weeds from PXC weeding stations and conveying themto a weed collection container 2011 or equivalent.

Weeding area 2010 PXC's may incorporate side walls extending a shortdistance above sides of PC's to prevent inadvertent movement of PA's byweeding workers. Weeding workers reach stations by overhead walkways(not shown) and may be provided with stools for comfort. PASsemi-automatic weeding area 2010 presents a comfortable weedingenvironment, presenting a tremendous improvement over conventional fieldhand weeding—an operation performed by workers who typically must bendover to reach and pull weeds. Conventional hand weeding has contributedto worker back injuries and has actually been banned in the State ofCalifornia. PAS 2000, including weeding area 2010, is under roof,enabling production during inclement weather and shading workers fromdirect sunlight, furthering comfort factor and associated workerproductivity. Finally, artificial lighting of PAS weeding area 2010provides for production at night as well as day.

PAS Embodiment 1 Operation

PAS 2000 can operate in following modes: open loop, containerclosed-loop, and pallet assembly (PA) closed-loop. These modes areachieved through recipe-driven, microprocessor-based control,substantial integration of controls and process and the ability of mostPAS 2000 components to operate reversibly.

Open-loop mode is characterized by generally single-direction movementof containerized plants through PAS 2000, and can have followingvariations: ‘serial-in’, ‘serial-out’, ‘serial-in/out’, ‘parallel-in’,and ‘parallel-out’.

‘Serial-in’ mode comprises: conveying of individual containerized plantsor trays/flats of plants from a location outside the nursery internalgrowing areas—typically the nursery's shipping/receiving area—to one PAU2100(2), along with conveying of pallets, and, if applicable, grids,from PGSU 4500(2) which singulated pallets from stacks drawn from PGSA3500, through PGSE 4510(2); installation by PAU 2100(2) of associatedcontainerized plants or trays/flats of plants into pallets; conveying ofcompleted PA's from PAU 2100(2), along PC path2003(B3)-2004(B3)-2005(B3)-2005(C3)-2005(A3)-2004(A3)-2003(A3), to PC's5002 and 5001 interfacing with PACTU 5000; and transfer by PACTU 5000 ofPA's from PACTU interface PC's 5002 and 5001 to a PATT 1200 fortransport to a nursery internal growing area. ‘Serial-out’ mode iseffectively the reverse of ‘serial-in’, though incorporates rinsing ofpallets, and, if applicable, grids, by PGWU 5700. This mode comprises:transfer by PACTU 5000 of PA's from a PATT 1200—received from a nurseryinternal growing area—to PACTU interface PC's 5001 and 5002; conveyingof PA's from PACTU interface PC's 5001 and 5002 to a second PAU 2100(1);removal by associated PAU 2100(1) of containerized plants or trays/flatsof plants from pallets and placement of containerized plants ortrays/flats of plants on CAIDOC 2107(1); conveying of pallets and, ifapplicable, nested grids, to and rinsing by PGWU 5700, conveying to andsubsequent stacking by second PGSU 4500(1), and conveying of resultingstacks to PGSA 3500—through PGSE 4510(1)—for temporary storage; and,conveying of containerized plants from associated PAU 2100(1) to alocation outside the nursery internal growing areas—typically thenursery's shipping area.

‘Serial-in/out’, ‘parallel-in’ and ‘parallel-out’ modes are possible dueto incorporation of two properly arranged PAU's 2100(1) and 2100(2) andassociated PC's and CPC's in the PAS 2000. ‘Serial-in/out’ ischaracterized by PAS 2000 split operation wherein a first part of thePAS 2000 operates in the ‘serial-in’ mode, like that described abovewhile a second part operates in ‘serial-out’ mode, also like thatdescribed above. Different plant material types and palletconfigurations would typically be processed by each part as the PAS 2000operates in ‘serial-in/out’ mode. Parallel-in' and ‘parallel-out’ modesare characterized by both parts of the PAS 2000 operating in ‘serial-in’and ‘serial-out’ modes, respectively. ‘Parallel’ PAS 2000 operationprovides for substantially increased system throughput relative tosingle, ‘serial’ operation, accommodating seasonal peaks, e.g., orderfilling/shipping.

Container closed-loop mode is characterized by: transfer by PACTU 5000of PA's of containerized plants or PA's of trays/flats of plants from aPATT 1200—received from a nursery internal growing area—to PACTUinterface PC 5001; conveying of PA's from PACTU interface PC 5001 to PAU2100(1); removal of containerized plants or trays/flats of plants, asapplicable, from the associated PA's by PAU 2100(1); conveying ofassociated containerized plants or trays/flats of plants, as applicable,from PAU 2100(1) to a central processing area (e.g., potting, individualplant weeding, pruning, inspection/grading/sorting, etc.); conveying ofemptied pallets and, if applicable, grids from PAU 2100(1) to PGWU 5700;washing of emptied pallets and, if applicable, grids by PGWU 5700;conveying of washed pallets and, if applicable, grids to PGSU 4500(1)and resulting stacks to PGSA 3500 for temporary storage; conveying ofstacks of pallets and, if applicable, grids,—potentially different fromthose stored immediately prior—from PGSA 3500 to PAU 2100(2); conveyingof containerized plants from central processing area to PAU 2100(2);installation of (potentially newly potted) containerized plants intoPA's by PAU1 2100(2); conveying of reassembled PA's from PAU 2100(2) toPACTU interface PC 5002; and transfer of reassembled PA's from PACTUinterface PC 5002 to PATT 1200—potentially the same as that on whichPA's were received—by PACTU 5000, for return to a nursery internalgrowing area. PAS 1500 may also simply remove containerized plants fromcontiguous container PA's 400, convey them through an idle or unmannedprocessing area, and install them into spaced container PA's 500.Further, if operation is limited to a pallet change from contiguous tospaced or vice versa, i.e., such that associated containers are notaltered and no manipulation or alteration of the plant itself isinvolved, PAU 2100(1) can simply reach across CAIDOC 2107(1) andretrieve individual containerized plants exiting PAU 2100(2) oncontainer conveyor 1700, with proper indexing control of containerconveyor 1700.

PA closed-loop mode is characterized by: transfer by PACTU 5000 of PA'sof containerized plants or PA's of trays/flats of plants, as applicable,from a PATT 1200—received from a nursery internal growing area—to aPACTU interface PC 5001; conveying of PA's as units from PACTU interfacePC 5001 to a central plant material processing area 2010 (e.g., weeding,pruning, inspection/grading/sorting, etc.) (FIGS. 49, 50, 51, and 54);conveying of PA's from central plant material processing area 2010 toPACTU interface PC 5002; and transfer by PACTU 5000 of PA's from PACTUinterface PC 5002 to PATT 1200—potentially the same as that on whichPA's were received—, for return to nursery internal growingarea—potentially substantially the same as that from which plantmaterial originated.

Pallet Assembly Greenhouse Transfer Unit (PAGTU) Embodiment 1

An autonomously guided pallet assembly greenhouse transfer unit (PAGTU)4000, in accordance with a first embodiment of the invention, isillustrated in FIGS. 62A-T. PAGTU 4000 provides for autonomous transferof PA's between PATT 1200 and potentially confined bed space 125, aswell as autonomous transfer of pallet and grid stacks between PATT 1200and potentially confined storage space—typically unused bed space. PAGTU4000 requires a relatively narrow operating path and low verticalclearance in order to perform these functions, and utilizes primarilyRTK GPS for resolution of its position and attitude, rendering PAGTU4000 ideal for operating inside a greenhouse, as well as out in a field.

First embodiment of PAGTU 4000 comprises a specialized forklift-typeunit having a tricycle traction wheel arrangement, where all wheels areservo position-driven. PAGTU main carriage 4020 comprises framework formounting two fixed-direction pneumatic tired traction wheels 4060(L) and4060(R), respectively mounting sync belt sprockets 4057(L) (not shown)and 4057(R), coupled sync belts 4056(L) (not shown) and 4056(R), coupleddrive motor sync belt sprockets 4055(L) and 4055(R), and servopositioning gearmotors 4054(L) and 4054(R), in protective shrouds4058(L) (not shown) and 4058(R). Main carriage 4020 also mounts via arotary joint 4083 having a vertical centerline a second carriage 4080,which, in turn, mounts two closely laterally spaced additional tractionwheels 4081(L) and 4081(R) driven by a common servo positioninggearmotor 4040 through differential 4084. This arrangement provides forminimal skidding of tires in tight turns. Main carriage 4020 also housesa battery or, alternately, a prime mover, e.g., a gasoline or dieselengine, and a fuel tank. Each alternative satisfies the need forcounterweight enabling PAGTU 4000 to maintain its stability duringlifting of heaviest PA's anticipated in operation. Finally, maincarriage 4020 houses PAGTU control system, including RTK GPS-relatedcomponents.

Second carriage 4080, best seen in FIGS. 62C and D, mounts to maincarriage 4020 through a rotary joint 4083 that swivels about a verticalaxis, driven by a servo positioning gearmotor 4036, through sync beltsprocket 4037, sync belt 4038, and sync belt sprocket 4039. Thisarrangement in part provides for active steering of PAGTU 4000. Mountedto PAGTU second carriage 4080 is a differential 4084, which, in turn,mounts on its two output shafts tired fraction wheels 4081(L) and4081(R). Differential input shaft centerline is common to verticalcenterline of PATU second carriage 4080 rotary joint. Differential isdriven by servo positioning gearmotor 4040, through sync belt sprocket4041, sync belt 4042, and sync belt sprocket 4043—mounted todifferential input shaft. This arrangement provides traction drive ofPAGTU 4000 swivel wheel. Programmable nature of control system enablespositioning steering and traction drive outputs to be mixed during PAGTUturning, averting slippage between traction wheels and the ground,thereby preserving high machine drive efficiency and minimal bed impact.

Third carriage 4100, best seen in FIGS. 62E and F, mounts to maincarriage 4020 through rotary joints 4064(L) and 4064(R) (not shown) thatprovide for pitching of third carriage 4100—and those mountedthereon—about a horizontal axis parallel to centerline common to maintraction wheels 4060(L) and 4060(R), relative to main carriage 4020.Pitch of PAGTU third carriage 4100 is driven by a servo positioninghydraulic or equivalent actuator pair 4062(L) and 4062(R), each actuatorof which is pinned to PAGTU main carriage 4020 at one end and to PAGTUthird carriage 4100 at the other end, allowing for inherent angularchanges between PAGTU main carriage 4020, actuators 4062(L) and 4062(R),and PAGTU third carriage 4100.

PAGTU third carriage 4100 also incorporates a pivoting joint 4121 and anarcuate track 4108 providing for pivotal mounting of fourth carriage4120—a lift mast—about an axis falling in a vertical plane centeredbetween traction wheels 4060(L) and 4060(R) and perpendicular to trackof lift mast 4120, i.e., roll. A servo gearmotor 4102, mounted to PAGTUthird carriage 4100, in turn, mounts a sync belt sprocket 4103. A firstend of a pair of laterally spaced open-ended sync belts 4105, attachesto a first end of an arcuate pulley 4107 that is part of PAGTU lift mast4120. Sync belt 4105 pair engages and is returned by gearmotor-drivensync belt sprocket 4103 and terminates at its second end at clip 4109.Clip 4109 couples second end of sync belt 4105 pair to first end of anopposing open-ended sync belt 4106, which engages and is returned byidler sprocket 4106, passes between spaced sync belts 4105, andultimately terminates at second end of arcuate pulley 4107.

Combination of PAGTU third 4100 and fourth 4120 carriages provide foractive programmable pitching and rolling, respectively of PAGTU fork4300, as necessary for PAGTU 4000 engagement of PA's in undulating bedspace that contains PA's that PAGTU 4000 must retrieve or that is toreceive PA's that PAGTU 4000 must place. It also enables a PAGTU 4000situated on a first ground surface plane to drive the plane of its forktines to be parallel with that of any deck of a PATT 1200 situated on asecond ground surface plane, which is not parallel to first groundsurface plane.

Fork lift mast 4120 incorporates linear bearings 4125, which, togetherwith linear bearings 4163 at the base of fork lift first stage 4160guide fork lift first stage 4160 along length of fork lift mast 4120.Fork lift mast 4120 also mounts a pair of laterally spaced hydrauliccylinders 4122(L) and 4122(R) or equivalent for driving fork lift firststage 4160 longitudinally along fork lift mast 4120. Upper end of forklift first stage 4160 incorporates pulleys 4164 and 4165. Fork lift mast4120 also mounts another hydraulic cylinder 4123 or equivalent, whichdrives downward, parallel to fork lift first stage motion, and has apulley block 4142 incorporated into its lower, downwardly extending end.An open-ended belt 4127 is fastened at a first end 4126 to fork liftmast 4120, then extends downward, parallel to fork lift first stage 4160motion, to and wraps half way around cylinder 4123—actuated pulley 4142.Belt 4127 then extends upward, parallel to fork lift first stage 4160motion, to fork lift first stage pulleys 4164. Belt 4127 wraps overcollective tops of fork lift first stage pulleys 4164 and 4165, andfinally extends downward, parallel to fork lift first stage 4160 motion,to a clamp 4187 on fork lift second stage 4180, where belt 4127terminates.

Fork lift first stage 4160 further incorporates a longitudinal tracktraversed by fork lift second stage, running on bearings 4182. Lightningrods 4167 and associated conductors and grounding electrodes are alsoprovided to protect PAGTU 4000 operating in a inclement weather

Extension of cylinder 4123 and related motion of pulley block 4142,while maintaining cylinders 4122(L) and 4122(R) retracted, drives forklift second stage 4180 longitudinally along fork lift first stage 4160as fork lift first stage 4160 remains retracted, fully nested in forklift mast 4120. Incorporation of pulley 4142 further causes distancetraveled by fork lift second stage 4180 to be double the stroke ofcylinder 4123. Operation of cylinder 4123 keeps fork lift height to aminimum to allow PAGTU 4000 to work inside a greenhouse, where ceilingheight is often limited, as depicted in FIGS. 62G-N. It also promotesPAGTU 4000 stability by keeping PAGTU 4000 center of gravity lowrelative to that resulting from a strict telescoping mast. Depictedarrangement, where cylinder 4123 is mounted in upper half of fork liftmast 4120 may be altered to further reduce PAGTU 4000 center of gravityby relocating cylinder 4123′ in lower half of fork lift mast 4120 andadding one more pulley immediately below it, such that belt 4127′extends from pulley 4165, downward to below pulley below relocatedcylinder 4123′, and up, over top of cylinder 4123—mounted pulley block4142′, and back down to terminating clip, yielding the same effect onPAGTU fork lift second stage 4180 as depicted arrangement.

Extension of cylinders 4122(L) and 4122(R) and related motion of forklift first stage 4160, while maintaining cylinder 4123 retracted, drivesfork lift second stage 4180 longitudinally along fork lift first stage4160 as fork lift first stage 4160 upwardly extends relative to forklift mast 4120. Incorporation of pulleys 4164 and 4165 further causesdistance traveled by fork lift second stage 4180 to be double the strokeof cylinders 4122(L) and 4122(R). Operation of cylinders 4122(L) and4122(R) causes telescoping of fork lift mast 4120, first stage 4160 andsecond stage 4180, enabling PAGTU fork 4300 to engage uppermost decks ofPATT 1200 for transferring PA's between PAGTU 4000 and PATT 1200, asshown in FIGS. 62P-S.

Mounted to fork lift second stage 4180 is an articulated fork 4300,joined to fork lift second stage 4180 by slender, pivoting,tandem-connected members 4200 and 4220. Members 4200 and 4220 and fork4300 swivel in a plane parallel to the one containing fork 4300 tines.Members 4200 and 4220 and fork 4300 also present a sufficientlyvertically compact assembly to operate between two adjoining decks of aPATT 1200. Fork articulation first drive servo gearmotor 4186 is mountedto fork lift second stage 4180. First end of fork first articulatingmember 4200 is mounted to and reciprocally driven by output shaft ofservo gearmotor 4186. Second end of fork first articulating member 4200mounts fork articulation second drive servo gearmotor 4204. First end offork second articulating member 4220 is mounted to and reciprocallydriven by output shaft of servo gearmotor 4204. Second end of forksecond articulating member 4220 mounts fork articulation third driveservo gearmotor 4224. Base of fork 4300 is mounted to and reciprocallydriven by output shaft of servo gearmotor 4224.

Two spaced GPS antennas 4022 and 4024 (along with other requisitePAGTU-borne GPS equipment) enable PAGTU position and attitude to bedetermined. Incorporation of position-measuring control system devicestypically associated with servo positioning system provide for accuracyof PAGTU RTK GPS-based attitude calculations to be increased witharticulated fork 4300 extended.

Coordination between fork articulation members to achieve straight-linemotion in substantially an infinite number of directions withinoperating plane of articulating members is readily achievable with PAGTU4000 programmable motion controls and stated servo devices. FIGS. 62G-Nillustrate a process whereby PAGTU fork 4300 engages and retrieves a PAlaterally adjoining a narrow lane earlier cleared of PA's by PAGTU 4000.FIG. 62G shows PAGTU 4000 entering area, with its fork 4300 horizontallyretracted and at an elevation in which tines readily pass over the topsof canopies of plant material adjoining lane cleared earlier by PAGTU4000. Strictly fork lift second stage 4180 is elevated while fork liftfirst stage 4160 remains retracted, keeping fork lift height to aminimum. FIG. 62H shows PAGTU 4000 having realigned its fork 4300 tomatch direction of planned engagement with target PA, while maintainingprevious elevation, thereby clearing the tops of canopies of adjoiningplant material as stated. At this stage, swivel traction wheel is turnedin anticipation of turning PAGTU to follow up fork 4300 to ensure astable state for lifting PA. FIG. 62I shows PAGTU 4000 having loweredits fork 4300 to match the elevation of the target PA, completingpre-engagement alignment with PA. Articulated fork members can finelyposition fork 4300 upon coarse positioning of more massive PAGTU maincarriage. FIG. 62J shows PAGTU 4000 having linearly and laterallyadvanced its fork 4300 into engagement with target PA. FIG. 62K showsPAGTU 4000 in the process of turning to align its track with fork 4300for stability as needed for handling a PA of relatively greater weight.FIG. 62L shows PAGTU 4000 having lifted target PA above tops of canopiesof adjoining plant material as necessary for further PAGTU maneuvering.FIG. 62M shows PAGTU 4000 with fork 4300 holding lifted target PA drawnhorizontally into alignment with PAGTU 4000 track, minimizing lateralprotrusions and maximizing stability for PAGTU 4000 travel to PAdrop-off point.

FIGS. 62P-S illustrate a PAGTU 4000 placing or retrieving a PA on anuppermost deck of a PATT 1200, on the side distal to the subject PAGTU4000. Telescoped configuration of subject PAGTU 4000 as necessary toreach PATT 1200 uppermost deck, is shown. Mast 4120 is pitched androlled as necessary for fork 4300 to achieve parallelism with PATT 1200decks. Fork articulation members 4200 and 4220 enable fork 4300 to reachfar side of PATT, as well as provide for fine lateral adjustment of fork4300 relative to target position on PATT 1200.

As can be seen in FIGS. 62P-S, auxiliary fork support wheels 4362(L) and4362(R), mounted to base of fork 4300, are automatically lowered byrespective pneumatic cylinders 4361(L) and 4361(R) to providesupplemental stabilization of fork 4300 as PAGTU 4000 reaches across thedeck of a PATT 1200 to place or retrieve a PA.

Details of a fork 4300 having tines 4350, the lateral spacing of whichcan be adjusted, are shown in FIGS. 62T and U. As shown in FIG. 62T, anoptional pantograph arrangement, comprising links 4353 and 4354, forcelinked tines 4351 and 4352 to be parallel to one another, therebystiffening central tines against lateral bowing. Such bowing tendency isinduced by pallet-centering gussets (discussed earlier), which tend todrive apart tines adjoining pallet support columns, where gussets areincorporated. Because alignment between of one row of pallet segmentsresults in alignment of all rows of pallet segments, incorporation of astiffening arrangement on outermost tines 4350 yields no substantialbenefit. Distances between tines are set to equal the diameters orequivalent at which the gussets meet the bottoms of the pallet containerreceptacles or the projected bottoms of the grids, as applicable.

Details of quick-adjusting/release fork tines 4350/4351/4352 are shownin the section view of FIG. 62U. Fork base 4301, with swivel motor shaftattachment 4302, incorporates a downward opening channel section, havingflanges with lips producing laterally tapered grooves 4303 and 4304opening toward one another on opposing sides of section, near bottom. Asuitable number of fork tine mounts 4321 having fingers 4322 and 4323,which engage respective grooves, are slid into engagement with fork base4301 from one end or the other of fork bas 4301. Each tine4350/4351/4352 is locked in place by squeezing of tine cam lock driverod arm 4337 against backup arm 4336. Cam lock drive rod 4329, in turn,pushes against spring 4327, which, in turn, pushes against cam lockactuation arm 4326, which rotates fork tine locking cam 4324 about pivotpin 4325 and against fork base groove 4304 wall. Pushing tine cam lockdrive rod arm 4337 sufficiently causes pawl 4334 of spring-loaded latch4332 to engage groove 4331 of cam lock drive rod 4329, holding cam lockdrive rod 4329 in place. A wedging action results in a tight frictionfit between tine mount 4321 and fork base 4301. Releasing fork tines4350/4351/4352 is achieved by squeezing of tine cam lock drive rod arm4337 against tine cam lock drive rod release arm 4335, then releasing.Squeezing action causes latch pawl 4334 to disengage groove 4331,thereby releasing tine cam lock drive rod 4329, etc. Pin 4339 maintainsengagement between tine cam lock drive rod 4329 and tine mount 4321.Recesses 4328 and 4330 provide space for spring 4327 of proper force andrate to achieve desired grip.

As is familiar to those skilled in the art, PAGTU 4000, regardless ofembodiment, incorporates safety sensors comprising radar, infrared, orequivalent, to safeguard personnel and equipment against potential harmby PAGTU 4000.

PAGTU 4000 preferably operates in automatic mode, wherein it maintainsan operational map, and automatically picks from a field or greenhouseand places on a PATT 1200, vice versa, or some combination thereof in anorder dictated by queues it maintains with updates radioed it by mastercontrol system. PAGTU 4000 also operates in a semi-automatic mode,wherein, an operator utilizes an RTK GPS-based probe (e.g. 180, FIG.64A) to pinpoint PA's and radio such information directly or indirectly(i.e., through master control system) to PAGTU for retrieval. PAGTU alsooperates in manual mode, wherein PAGTU takes “direct” instruction froman operator with a radio HMI. Manual mode may still entail PAGTU controlsystem-based coordination of fork articulation members to enable fork torespond to stroking of a joystick with linear motion.

Pallet Assembly Field Transfer Unit (PAFTU) Embodiment 1

A first embodiment of a PAFTU 1100, shown in FIGS. 1, and 63A-I,comprises an autonomously guided mobile bridge 1102 with a longitudinaltrack 1103, which a servo-driven pallet assembly handling first carriage1114 traverses. Bridge 1102 operates above and provides for servicing ofone or more nursery beds 125. Bridge 1102 is at sufficient height topass over irrigation sprinkler heads 129, which are normally elevatedvia vertical risers 130 above anticipated tops of plant materialcanopies 223. Position of bridge 1102 is detected at two GPS antennas1104 and 1105—one located at each end of bridge 1102—, providing forderivation of attitude (including heading) and velocity of bridge 1102.GPS antennas 1104 and 1106 feed a GPS receiver 1111 operating in RTK GPSmode. GPS receiver 1111 also receives GPS error correction radio signal120 from GPS base station 112, needed for RTK GPS mode. PAFTU controlsystem 1129 also via a radio link 122 communicates with master controlsystem at base station 112 to obtain operating instructions and providefeedback. Water-resistant design and lightning rods 1160, located atmachine high points, facilitate machine operation in inclement weather.Heavy copper electrical conductors carry lightning borne electricalcurrent to grounding electrodes 1161 on extreme ends of machine, alongpaths reasonably distal to sensitive machine control system electronics.

As shown in FIG. 63A, Bridge 1102 is supported by two bridge supports1116 and 1119 which are each, in turn, supported by two servo-steered,servo-driven traction wheel assemblies 1124. Traction wheel assemblies1124 are each attached to each bridge support 1116 and 1119 through ajoint that provides for swiveling of each traction wheel 1125, about avertical axis centered on the traction wheel 1124. Steering of tractionwheels 1124 is accomplished via servo drive of each swivel joint 1126.Steering of each traction wheel 1124 provides for preferred workingmovement of pallet assembly field transfer machine 1100 lateral tobridge 1102 longitudinal axis, as well as travel movement of machine1100 parallel to bridge 1102 longitudinal axis, thus enabling machine1100 travel on typical nursery vehicular driveways 127. Further, PAFTU1100 may turn about any radius of curvature, including zero, i.e., aboutthe center of machine 1100, for maneuvering in tight areas.

PAFTU bridge supports 1116 and 1119 engage bridge 1102 via a secondtrack 1115 on bridge 1102, providing for adjustment of longitudinalpositions of bridge supports 1116 and 1119 on bridge 1102. Adjustabilityof positions of bridge supports 1116 and 1119 provides for operation oftraction wheels 1125 in aisles 126 between relatively narrow beds 125while simultaneously having one end of bridge 1102 positioned proximalto one side of a driveway 127, on either end of bridge 1102, where aPATT 1200 operates, thereby facilitating pallet assembly transferbetween PAFTU 1100 and PATT 1200. Adjustability of positions bridgesupports 1116 and 1119 also enables bridge supports 1116 and 1119 tooperate on paths that are clear of irrigation sprinkler heads 129 andrelated exposed plumbing 130. Failsafe brakes 1117 and 1122, whichprovide for fixing positions of both bridge supports 1116 and 1119 alongbridge 1102, are interlocked to fix at least one bridge support 1116 or1119 at all times for safety.

Adjustment of positions of bridge supports 1116 and 1119 along bridge1102 may be accomplished one at a time automatically by a programmedsequence comprising: release of strictly brake 1117 or 1122 which freesthe position on bridge 1102 of one bridge support 1116 or 1119;swiveling of both traction wheels 1125 on one bridge support 1116 or1119 to drive parallel to one another and generally along longitudinalaxis of bridge 1102; activating associated traction wheels 1125 to driveswiveled bridge support 1116 or 1119 to achieve the desired position ofthe “free” bridge support 1116 or 1119 on bridge 1102; then reapplyingthe released brake 1117 or 1122. Such an adjustment can be accomplished‘on the fly’—either traveling or working—through a similar sequence.Encoders or equivalent position measuring devices, or even an RTK GPSantenna mounted on each bridge support 1116 and 1119 can providesuitable bridge support position information. Physical travel stops 1118and 1123 limit movement of bridge supports 1116 and 1119 along bridge1102 to ensure stability of bridge 1102.

PAFTU prime mover 1127, comprising an internal combustion engine drivingan electrical alternator with a DC rectifier package, is preferablysituated with its fuel tank 1128 at a relatively low elevation on one ofthe bridge supports 1116 or 1119, to aid in lowering the machine'scenter of gravity, thus, promoting machine stability. The internalcombustion engine further has an in-line cylinder arrangement tominimize prime mover 1127 width, in keeping with the desirability oflocating bridge supports 1116 and 1119 in space above relatively narrowaisles 126 between nursery beds 125.

Pallet handler first carriage 1114 houses the machine's master controlsystem 1129 and operates semi-autonomously on bridge 1102. Pallethandler first carriage 1114 obtains electrical power through electricalbrush-type contacts that run against a bus bar 1132 extending the lengthof bridge 1102. Similar arrangements provide for electrical powertransmission between bridge supports 1116 and 1119 and bridge 1102.Low-level control signal communication between bridge 1102, bridgesupports 1116 and 1119 and pallet handler first carriage 1114 arepreferably accomplished via radio or infrared links between thosecomponents. Near real-time control/status communication among allcommunicating machine components and between PAFTU 1100 and mastercontrol system at base station 112 assures overall system integrityrequired for safe autonomous operation.

As shown in FIG. 63B, pallet handler first carriage 1114 incorporates afirst linear bearing assembly 1121 movably attached to bridge track1103, as well as a second linear bearing assembly 1133 movably attachedto vertical linear track 1134 of a slender second, elevator, carriage1135 of pallet handler. Pallet handler first carriage 1114 furtherprovides servo drive for movement of attached pallet handler elevatorcarriage 1135 along track 1134. Lower end of pallet handler elevatorcarriage 1135 connects to one end of a linear, slender pallet handlerthird carriage 1138 through a rotary joint 1137 having a servo-drivenangular positioner which swivels pallet handler third carriage 1138 inyaw substantially about longitudinal vertical centerline axis 1136 ofpallet handler elevator carriage 1135. Opposite end of pallet handlerthird carriage 1138 also has a swivel joint 1141 with a servo-drivenangular positioner for swiveling, also in yaw, a fourth carriage 1143,which acts as a wrist for the remaining carriages making up a forkassembly. Fourth carriage 1143 connects through horizontal swivel joint1144 to a fifth carriage 1145. Swivel joint 1144 provides for minorrolling motion of assembly of succeeding carriages, accommodatingmachine operation on ground that undulates in direction lateral to forktines. Fifth carriage 1145 is elongated perpendicular to swivel joint1144, generally horizontally. Protruding from the longitudinal ends offifth carriage 1145, and aligned with one another are swivel joints1146, which provide for minor pitching motion of assembly of succeedingcarriages, accommodating machine operation on ground that undulates indirection parallel to fork. Succeeding carriages are effectively a forkassembly, having a base 1147.

Fork 1147 is movably attached to fork pitch rotation joint 1146 and isshown having size suitable for handling of one PA 300, 400 or 500,though could be potentially sized to handle more than one PA's 300, 400or 500 simultaneously. Fork tines 1153 are shaped and spaced to providefor lifting of PA's 300, 400 or 500 from beneath bottoms of mountedcontainerized plants 200 as discussed above. Preferably, spacing andnumber of fork tines 1153 are adjustable to correspond to the number ofcontainer receptacle rows in handled PA's 300, 400 or 500.

As shown in FIGS. 63C-G, PAFTU 1100 provides for automatic lifting andtransferring PA's 300, 400 or 500, either from a nursery bed 125 to anavailable space on a proximal autonomously guided pallet assemblytransport train 1200, or vice versa, while maintaining traction wheelsoutside of nursery bed 125 space. For high positioning accuracy, RTK GPSantennas 1104 and 1106 are mounted at the longitudinal ends of bridge1102 and high-resolution position encoders or equivalent, along withstrategically situated discrete proximity or equivalent sensors/switchesand numerous programmed position, velocity, and accelerationcalculations in the PAFTU control software, locate PAFTU elementsrelative to RTK GPS antennas 1104 and 1106. One or more GPS antennas,while not shown, may as well be incorporated into fork for positionsensing. Coordinated movement of pallet handler first carriage 1114along bridge 1102 and rotation of pallet handler third carriage (link)1138 about yaw swivel axes 1136 and 1139 at two ends of pallet handlerthird carriage (link) 1138 accomplishable through circular numericalcontrols (CNC), enables fork 1147 to move linearly, generallyperpendicular to bridge 1102 to engage PA's 300, 400 or 500 withoutmovement of bridge 1102, itself. Dual yaw swivel joints of pallethandler third carriage 1138 and coordinated movement by same elementsalso allows for compensation in placement of PA's 300, 400 or 500 on orretrieval of PA's 300, 400 or 500 from coarsely positioned PATT 1200,wherein linear movement of fork 1147 in a direction typically generallyparallel to bridge 1102 longitudinal axis is necessary.

FIGS. 63H and I depict two different nursery bed configurations, 125(A)and 125(B), respectively, which can be serviced by PAFTU 1100 and anassociated PATT 1200, and configurations of PAFTU 1100 necessary forsuch servicing. FIG. 63H depicts beds 125(A) having narrow aisles 126(A)in which PAFTU 1100 traction wheels operate upon proper alignment ofbridge supports 1116 and 1119 with such aisles 126(A). These aisles126(A) are automatically selected over similar aisles having irrigationsprinkler heads 129(A). Parallel to narrow aisles 126(A) are driveways127(A) interspersed at key locations for operation of PATT 1200,suitable for interacting with PAFTU 1100.

FIG. 63I depicts beds having narrow aisles 126(B) that run perpendicularto and between driveways 127(B) on which PAFTU 1100 traction wheelsoperate with proper alignment of bridge supports 1116 and 1119. In thiscase, bridge support 1116 is placed across a first driveway 127(B1) fromPAFTU 1100—engaged bed 125(B) to enable PAFTU 1100 to engage PA's in adirection parallel to bridge 1102. Bridge support 1119 is placed in asecond driveway 127(B2), adjoining PAFTU 1100—engaged bed 125(B). Nextto bridge support 1119 in driveway 127(B2) is PATT 1100, situated tointeract with PAFTU 1100.

Nursery Automation System Mapping Tools

Automation in accordance with invention necessitates digitally mappingthe nursery automation system operating area 111 (FIG. 1) utilizing RTKGPS-based mapping tools. Given that RTK GPS requires establishment of abase station for receiving GPS satellite signals and providing a fixedGPS satellite signal receiving point to which base station GPS receiverrefers in the generation of an error correction signal, such basestation 112 and associated reference point must be established prior toutilization of RTK GPS-based mapping tools. Upon establishment of suchfixed reference point and GPS base station 112, physical features ofautonomous machinery operating area 111 of nursery are then mapped bypersonnel 133 roving the area with one or more hand-held mapping units(FMUH's) 180 (FIGS. 64A-D) and, preferably with a trailer-based remotemapping system (FMSRT), which comprises a pair of specially-configuredtrailers 150 (FIGS. 64A, B) for towing preferably behind utilityvehicles.

Feature Mapping Unit-Hand-Held (FMUH)

FMUH 180 incorporates: a computer/human machine interface (HMI) terminal186; two GPS satellite signal antennas 182 and 183; an RTK GPS errorcorrection signal antenna 197; an inclinometer 184 providing computer186 with accurate unit inclination information; a non-contact distancetransducer 185 providing computer 186 with height of transducer 185(and, thus, unit) above ground; a component mounting plate 181 andriser/grip bar 187; riser clamp angle transducer 199 for measuring riserdiameter; a sprinkler riser mounting seat 190, associated spring194—loaded clamp 191, pivot pins 188 and 196, linkage 193, and releasehandle 189. Dual satellite antennas enable FMUH 180 to determine itsheading as well as position without having to be moved. (Such canalternatively be accomplished with a flux valve/electronic compass.)

FMUH 180 arrangement provides for mounting to and mapping of irrigationsprinkler heads, including their heights, attitudes (tilt angle anddirection) and riser diameters. Also, an attachable probe 198 (FIG.64C), the bottom of which is for contacting the ground, can beincorporated to map other nursery features. These include, but are notlimited to, machine storage areas, staging areas, serviced nursery beds125, aisles 126 between serviced nursery beds 125, and serviceroads/machine travel paths 127. Data logger portion of FMUH 180incorporates pre-programmed data entry types selectable by mappingpersonnel 133 for facilitating mapping expediency. Some sample datatypes include: nursery bed corner, sprinkler head position, sprinklerriser base position, driveway corner, greenhouse outer corner,greenhouse doorway outer corner, machine storage building/shed doorwayouter edge, etc. FMUH 180 incorporates sensors and programming thatautomatically detect and compensate for position offset of attachedprobe 198. FMUH 180 further provides a real-time graphical display,depicting portion of nursery being mapped, giving feedback to mappingpersonnel, promoting proper data entry. Resulting topographicalrepresentation of nursery service areas ensures accurate placement andretrieval of pallet assemblies 300, 400 and 500, as well as physicalorientation stability of operating autonomous machinery.

FMUH 180 can also be used in production situations for reestablishingpositions and plan orientations (headings) of PA's that may have beendisplaced by floodwaters, extremely high winds, or inadvertent manualcontact. Simple probing of two predefined corners of pallet formingsubject PA, together with FMUH control system knowledge of associated PAgeometry, establishes requisite subject PA. Further, FMUH controlsystem, with knowledge of pallet geometry and production status (i.e.,pallet type that should be present) FMUH can audibly and visually alertoperator to probing errors, ensuring proper determination of positionand plan orientation of subject PA. Once position and plan orientationof subject PA has been reestablished, FMUH 180 can transmit via radiosuch information to master control system, which, in turn, provides suchinformation to pertinent autonomous material handling machinery forsuccessful retrieval/handling of subject errant PA.

Feature Mapping System-Remote, Trailer-Mounted (FMSRT)

Many nurseries incorporate irrigation sprinkler heads that arepositioned centered in relatively wide beds, making direct access tothose heads for mapping a time-consuming effort. A remote,trailer-mounted, feature mapping system (FMSRT) in accordance with theinvention, substantially expedites mapping of such difficult-to-accesscomponent with sufficient accuracy to avert collisions betweenautonomous pallet-handling machinery while promoting placement of PA'srelatively closely to such features, thereby maximizing use of bedspace.

FMSRT, illustrated in FIG. 65A, comprises two substantially identicaltrailer-based units that complement one another, working together tovisually map relatively distant, difficult-to-access nursery features,e.g., sprinkler heads, while each trailer operates on a nearby driveway.

Each trailer comprises a metal frame on two wheels, having a towbar/hitch for towing behind a small utility vehicle. One of the twowheels incorporates a rotary incremental encoder 157 or equivalentrotary position-measuring device for interpolating associated trailerposition between GPS position updates, as needed. Also mounted to frameis a first carriage 174 that swivels about a vertical axis and isclamped a fixed position for a given mapping operation. Also mounted toframe is an electrical enclosure in which control system is found.

First carriage 174, with the exception of the swivel joint, comprises aframework that is of triangular shape falling in a vertical plane, whichis centered between two trailer wheels with swivel centered. One upperedge of triangular frame of first carriage 174 is sloped preferably 45degrees to typically horizontal trailer deck. First carriage 174, inturn, mounts a light source 170, a light source vertical positiontransducer 173, two GPS satellite antennas 153 and 154 spaced apart toenable trailer attitude/heading to be measured; an RTK GPS errorcorrection signal antenna 155, and second carriage 175 that provides forreversal of the aperture of a thereon-mounted linear photoelectricreceiver array.

Second carriage 175 comprises primarily a photoelectric sensor array172—a linear array of photoelectric sensors spaced a short distance(e.g., ½-inch or less) apart in a slender housing pinned at its ends,allowing for swiveling of sensor array 172 about its longitudinal axis.Sensors have separate electrical output circuits that enable sensorarray 172 to iteratively roughly measure lengths of objects that passbetween a point light source and sensor array 172. Height of sensorarray 172 is sufficient to ensure all target features can be reliablymeasured. Second carriage 175 is arranged for periodic rotation aboutits slender body, effectively “flipping” over to view source light fromthe opposing side. Orientation of sensor array 172 is maintained byspring-applied latch 176. Light source and photoelectric receivers arepreferably modulated to negate error-producing effects of ambient lighton the photoelectric receivers. Photoelectric sensor array 172 is slopedto enable light from source to be received on both sides of a slendertarget feature, e.g., a sprinkler riser, providing for redundancy inmeasurement of such feature.

Frame-mounted electrical enclosure holds a microprocessor-basedprogrammable control system 151, including GPS receiver 152. Ahuman-machine interface (HMI) terminal 160, separate from FMSRT control151 enclosure, mounts on handle bar or dashboard of utility vehicle andis connected through a cable 161 to control system enclosure atconnector 162. FMSRT preferably draws electrical power from utilityvehicle electrical supply (e.g., alternator or battery), thoughalternately could have its own battery. Control system incorporateselectrical circuitry and real-time programming suitable for relativelyhigh rate data logging. Discrete inputs comprise primarily photoelectricreceiver signals (light/dark) and operator HMI terminal 160 inputs.Digital inputs comprise GPS satellite and base station signals, encoder157 signal, light source height transducer 173, HMI terminal 160signals, and current time. System output comprises time-stamped positionand photoelectric sensor array status data sent to permanent storage andoperator audiovisual travel speed command information via the HMIterminal 160.

Prior to a mapping operation, each of two FMSRT trailers 150(1) and150(2) are arranged in an initial configuration. In initialconfiguration, each trailer has its first carriage 174 setcounterclockwise 45 degrees in plan from vertical plane centered betweentrailer wheels. The second carriage 175 of first trailer 150(1) is setto receive light input from its right-hand side, while the secondcarriage 175 of second trailer 150(2) is set to receive light input fromits left-hand side. Light source 170 on each trailer is set to anelevation a minor distance above the tops of the canopies of the plantmaterial in the bed container the target sprinkler head(s).

As shown in FIG. 65B, first utility vehicle with trailer 150(1) isstaged on a driveway adjoining a bed containing features (e.g.,sprinkler heads) to be mapped, wherein subject bed is to right oftrailer 150(1). Second utility vehicle with trailer 150(2) is staged ona driveway adjoining a bed containing same features (e.g., sprinklerheads) to be mapped by utility vehicle/trailer 150(1), wherein subjectbed is to left of trailer 150(2). Utility vehicle/trailer 150(1) leadsutility vehicle/trailer 150(2) so as to cause light source 170 on onetrailer to be normal to the photoelectric receiver array 172 on thecomplementary trailer. I.e., utility vehicle/trailer 150(1) leadsutility vehicle/trailer 150(2) by the width of the bed between them.

First 150(1) and second 150(2) utility vehicle/trailers are establishedas master and slave, respectively, in a master/slave data collectionarrangement. Master (first) utility vehicle/trailer 150(1) travelsindependently to a pre-defined speed limit, while slave (second) utilityvehicle/trailer 150(2) speed—generally the same as that of the master—isset and adjusted as necessary to maintain a fixed lead distance frommaster (first) utility vehicle/trailer 150(1) so that photoelectricarray 172 on a given trailer is maintained normal to the light source170 on the complementary trailer. Real-time GPS position of FMSRT master(first) trailer 150(1) is radio communicated to slave (second) FMSRTtrailer 150(2) control system, which compares the received positioninformation to proper offset information it maintains, generating anerror value, which drives an audible indication (i.e., tone) produced byHMI, prompting slave (second) utility vehicle operator to increase ordecrease his speed to reduce the error value—effectively yielding aposition servo loop. Speed control tones, based on a pre-defined workingspeed, can also be incorporated into master utility vehicle/trailercontrols. Incorporation of pair of headphones, connectable to HMI,facilitates operator concentration on speed control tones.

Alternately, an auto-throttle system could be incorporated into eachutility vehicle, wherein master would travel at a constant speed andslave would maintain the discussed offset distance. Safety would dictateincorporation of a ‘dead man’ switch on each vehicle to disengage theauto-throttle system in the event of a problem.

Data acquisition initiates and vehicles/trailers travel length of bed ata rate limited by the lesser of the data acquisition update rate orsafety limits. While traveling, target features (e.g., sprinkler heads)are passed, which break the light beams emitted by the trailer lightsources 170(1) and 170(2) and received by parts of the correspondingphotoelectric receiver arrays 172(2) and 172(1), giving rise to heightmeasurements and a first of two attitude measurements of featuresobserved.

Upon completing initial pass(es), first carriage 174 of each trailer 150is swiveled to 45 degrees clockwise in plan from vertical plane centeredbetween trailer wheels. The first vehicle/trailer 150(1) now leads thesecond vehicle/trailer 150(2) by the distance it trailed the secondvehicle/trailer 150(2) in the earlier configuration as data collectionis resumed. This results in triangulated views of the remote featuresbeing mapped. Data consolidation and reduction, subsequent tocollection, yields positions of targeted remote features laterallyacross beds, in addition to longitudinal positions, heights, attitudes,and diameters (of risers). Manual counting of targeted features (e.g.,sprinkler heads) can be employed confirm system operation. Reduced datais in a format suitable as a digital map interpretable by nurseryautomation system in directing autonomous machinery.

Pas Embodiment 2 Physical Description

Unless otherwise stated, components incorporated into PAS secondembodiment are substantially the same as those incorporated into PASfirst embodiment.

A second embodiment of PAS 1500 is shown in FIGS. 66 and 67. This secondembodiment comprises: a second embodiment of a PGSU 1560, with fourpallet/grid stack conveyors (PGSC's) 1506, 1507, 1508, and 1509, and apallet elevator (PE2) 1640 with integral PC 1641; two PAU's, 1700(1) and1700(2), a PACTU 1820; and PC's 1860, 1870, 1870′ and 1890 forinterconnection of above components; thereby forming a first PC line.PAS 1500 further comprises PC's 1900, 1910, 1920 and 1930, and a PAshuttle 1940 with integral PC 1941, forming a second PC line, forsemiautomatic PA unit processing, described below.

First PC line in PAS second embodiment is an over-and-underconfiguration, reducing system footprint relative to first embodimentthough necessitating greater height to enable items conveyed on lower PCrun to pass beneath PAU's 1700. Further, access to PATT 1200 by PACTU1820 consequently necessitates bottommost deck of PATT 1200 be higherthan that of first embodiment, thus necessitating a ramp on which PATT1200 sits for loading and unloading, or the placement of lower PC's ofPAS second embodiment in a trough.

PAS second embodiment calls for stacks of pallets and grids to beremoved from PAS by forklift for storage elsewhere. Thus, no PGSA isincorporated in PAS second embodiment.

Also, PC's 1860 and 1890 may be elongated to provide space for anoptional PGWU with PGRU's comparable to those of PAS first embodiment.PC 1860 operates beneath such components.

Pallet/Grid Stack Conveyor (PGSC) Physical Description

As can be seen in FIGS. 68 and 69, four closely laterally spaced,parallel, substantially identical, pallet/grid stack conveyors (PGSC's)1506, 1507, 1508, and 1509 are located proximal and lateral to one endof a first, linear, PC line forming a PAS second embodiment 1500. Flowof each PGSC is bi-directional, horizontal and perpendicular first PCline and is servo-driven with positioning capabilities. Each PGSC is atleast as wide as the widest pallet PAS is configured to process, and atleast twice as long as the longest pallet PAS is configured to process.Belts of PGSC's are at lowest elevation of all PAS conveyor belts,matched only by those of PE1-PE2 and (during part of PE2 cycle) PE2PC's.

Proximal to first end 1529 of each PGSC, which is distal to longitudinalcenterline of PE1-PE2 PC described below, is an arrangement forcentering and squaring pallet and grid stacks 1540 and 1543,respectively, placed on associated conveyor at associated end 1529 by amanually operated forklift 1502. Arrangement consists of a lift table1511 and a pair of mirrored centering arms 1517 and 1518 situated onsides of PGSC opposite one another at associated conveyor end 1529. Lifttable 1511, the main structure of which is below conveyor belt supportstructure proximal to conveyor end 1529, incorporates ribs 1512 thatextend up between individual conveyor belts to provide a compositeplanar horizontal surface for lifting and subsequent lateral sliding ofpallet and grid stacks 1540 and 1543, respectively, without disturbingconveyor belts. Cam plate 1513, pushed horizontally by actuator 1514,and situated between lift table 1511 and stationary base plate 1516,drives lift table 1511 vertically upward along guides 1515,substantially synchronously raising upper surfaces of ribs 1512 aboveupper surfaces of adjoining conveyor belts, taking weight of pallet/gridstack from associated conveyor.

Push arms 1517 and 1518 operate as pantographs driven by cranks 1519 and1520, which are driven by links 1521 and 1522, respectively, which aredriven and guided by actuator 1525. A sensor at the end 1529 of eachPGSC, plus control system logic detect and establish the new presence ofa pallet/grid at the end 1529 of the associated PGSC. Lift table 1511 iselevated and then push arms 1517 and 1518 advance toward one another.One arm, 1517 or 1518, as applicable, contacts and pushes an eccentric,skewed pallet/grid on a corner pallet/grid support column, causingpallet to rotate until arm contacts other pallet/grid support columnsalong same side of pallet. At this point, pallet is rotationally alignedwith PGSC. Arm, 1517 or 1518, as applicable, continues pushing pallet,translating it toward PGSC center, at which point opposing arm, 1518 or1517, as applicable, contacts opposing side of pallet. At this point,pallet is rotationally aligned with and laterally centered above PGSC.If no other associated conveyor indexing action is occurring at thetime, associated lift table 1511 is then lowered, placing pallet/grid onassociated conveyor composite belt, properly oriented for conveying toPGSU for subsequent de-stacking. Pallet detection sensors and algorithmshandle remaining pallet indexing/positioning requirements of PGSU onpallet. Pallet alignment function works as well with custom pallets forholding PGSU pallet adapters, providing for automatic PGSU toolingchanges.

PGSU Embodiment 2 Physical Description

As shown in FIGS. 68 and 69, PGSU 1560 in a second embodiment of theinvention, as applicable to a particular operating mode, transferspallets 302, 402, or 502, and grids 600 (402, 502, and 600 shown)between PC's 1890, 1631 and PGSC's 1506, 1507, 1508, and 1509. PGSU 1560comprises framework 1562 and mutually interconnected first through fifthmanipulator carriages, 1568, 1575, 1588, 1594, and 1600, respectively.

Frame 1562 is arranged to enable PGSU 1560 manipulator carriages toengage pallets and grids situated on proximal ends of four PGSC's 1506,1507, 1508, and 1509, PGSU-PAUL PC 1890, and PE1 PC 1631. Frame 1562incorporates a linear, horizontal first track 1563—perpendicular toPE1-PE2 PC flow directions—for movable attachment of a first carriage1568. Also mounted between frame 1562 and first carriage 1568 is aservomotor/sprocket/gear belt arrangement for reciprocally driving afirst carriage 1568 along first track 1563.

Mounted to first carriage 1568 is a first set of linear (or camfollower) bearings 1569, which provide for movable attachment of firstcarriage 1568 to first track 1563 of frame 1562. Also mounted to firstcarriage 1568 are four vertical linear bearing arrangements 1570, 1571,1572, and 1573, each for movable attachment of second through fifthcarriages 1575, 1588, 1594, and 1600 via linear tracks 1576, 1589, 1595,and 1601, respectively, mounted thereon. Mounted between first carriage1568 and each of the second through fifth carriages is a servo actuatoras described above for reciprocally driving same along respective tracks1576, 1589, 1595 and 1601. Also mounted between first carriage 1686 andeach of second through fifth carriages 1575, 1588, 1594, and 1600 is afailsafe brake for emergency and idle fixing of same relative toassociated bearing arrangement, and a “counterbalance” pneumaticcylinder as described above.

Each of second through fifth carriages, 1575, 1588, 1594, and 1600,respectively, are substantially the same as the second and thirdcarriages of PGSU first embodiment.

Pas Embodiment 2 Operation

PAS second embodiment operates similarly to PAS first embodiment. Also,pallet and grid stacks are added to and subtracted from PAS via forkliftinterfacing with a PGSC's of PGSU second embodiment.

Pas Embodiment 2 Serial/Pallet Type Change Operation Pallet/GridAddition to PAS

In each PAS 1500 operating mode involving assembly of PA's combined withchange of type or addition of pallets 302, 402, or 502, such processstarts with placement of a stack 1543 of pallets 302, 402, or 502 and,if applicable, a stack 1540 of grids 600 onto forklift interface ends1529 of stationary PGSC's, 1507 and 1506, respectively, by a manned orautonomous forklift 1502. PGSC's provide for addition of pallet and gridstacks to PAS 1500 without interruption of continuous operation of PGSU1560 and, thus, PAS 1500.

Upon clearing of gripper interface end 1530 of PGSC 1507, PGSC 1507indexes a pallet stack 1543 from forklift interface end 1529 to gripperinterface end 1530 of PGSC 1507, clearing forklift interface end 1529 toreceive an additional pallet stack 1543. PGSC 1506 operates similarly,typically handling grids in lieu of pallet stacks. PAS 1500 then signalsfor additional pallet stacks (e.g., through illumination of a light andsounding of a horn for manual forklift operation, or, throughelectrically wired signaling to control system for autonomous forkliftoperation) and continues to operate without interruption. All PGSC's areindividually controllable by conveyor-dedicated clutch/brake units 1531positioned in the conveyor drive train between conveyor drive rollersand one common conveyor drive motor 1532, or by separateconveyor-dedicated drive motors, to enable independent indexing ofPGSC's 1506, 1507, 1508, and 1509. Thus, it is permissible for palletstacks 1544 and grid stacks 1541 to have different quantities of pieces,without interrupting PAS 1500 operation. Photoelectric sensors ormechanical limit switches 1535 detect passing leading or trailing edgesof pallet stacks 1544, establishing positions of pallet stacks 1544 onPGSC 1507. A similar sensor arrangement is incorporated on PGSC 1506.These discrete signals are fed to the programmable servo system controlsalong with conveyor position measurement information from positionmeasuring components—typically rotary encoders—associated with servosystem driving PGSC's, 1506, 1507, 1508, and 1509, respectively. Thisarrangement provides for flexible positioning on respective conveyors ofpallet stacks 1544 and grid stacks 1541, the geometry of each of whichmay change with production changes, due to different types of pallets300, 400 or 500 and grids 600 which system 1500 desirably handles.

Pallet stacks 1544 and grid stacks 1541 conveyed to gripper interfaceends, 1530 of PGSC's 1507 and 1506, respectively, are roughly positionedfor de-nesting due to variation in pallet stack 1543 and grid stack 1540placement positions and orientations on first ends 1529 of PGSC's 1507and 1506, respectively, by forklift 1502. PGSU 1560 compensates, asdescribed below, for such variation in positions and orientations ofpallet stacks 1544 and grid stacks 1541.

Pas Embodiment 2 Pallet/Grid Removal from Pas

Pallet/Grid Removal from PAS

In each process involving removal of pallets and, if applicable, grids,from PAS 1500 and subsequent storage of such items starts with thepresence of first and second pallets, 1894 and 1895, respectively,(similar to 302, 402, or 502) proximal to PGSU 1560 end 1893 of andspaced laterally on PC 1890. It may, depending on productionconfiguration, also start with the presence of a first pair of grids1896 and 1897 (similar to 600) beneath respective pallets 1894 and 1895and a second pair of grids 1896′ and 1897′ between respective pallets1894 and 1895 and PGSU 1560 end 1893 of PC 1890. Such process comprisessequentially: engaging and gripping a first pallet 1894 and, ifapplicable, a first grid 1896′, as applicable, on side of gridlongitudinal center vertical plane distal to PGSC's 1508 and 1509,transferring first pallet 1894 and grid 1896′ to and nesting them ontops of second pallet 1895 and grid 1897′, respectively, on side of PClongitudinal center vertical plane proximal to PGSC's 1508 and 1509;releasing first pallet 1894 and grid 1896′; gripping second pallet 1895and grid 1897′, thus capturing first pallet 1894 and grid 1896′,transferring first and second pallets 1894 and 1895, respectively, andfirst and second girds 1896′ and 1897′, respectively, to and nestingthem on tops of pallet stack 1553 and grid stack 1550 at PGSU 1560 ends1530 of PGSC's 1509 and 1508, respectively. Pallet and grid stacks 1553and 1550, respectively, on reaching designated size, are automaticallyconveyed from gripper interface end 1530 to forklift 1502 interface end1529 for forklift 1502 retrieval and transport to storage area.

Forklift 1502 places a stack 1507 of pallets 302, 402, or 502 and, ifapplicable, a stack 1542 of grids 600 onto stationary pallet stackconveyor belt 1509 and grid stack conveyor belt 1543, respectively,proximal to the first (free) end 1527 of a pallet stack conveyor 1517and grid stack conveyor 1540, respectively, These conveyors are oflengths of at least twice the horizontal dimension of the associatedstack 1507 or 1542 in the stack conveyor flow direction 1526 and providefor addition of pallet and grid stacks to system without interruption ofcontinuous operation of PGSU. Conveyor surfaces preferably comprisemultiple, laterally spaced gear belts 1525 for positive belt surfacepositioning and belt side-to-side “walking” elimination. Slide bedspreferably support conveyor belts for smooth operation and preferablyhave high-friction backing to promote substantially slip-free contactbetween belts and carried items.

In de-nesting mode, if grids 600 are to be incorporated into PA's 500(for example), PGSU 1560 picks up two grids 600 simultaneously from twogrid stacks 1542 at second end 1547 of grid stack 1540, translates grids600 and places them on first end 1644 of PC 1640. PGSU 1560 then picksup two pallets 502 simultaneously from two pallet stacks 1507 at secondend 1528 of pallet stack conveyor 1517, translates pallets 502 andplaces them on first end 1644 of PC 1640, inserting them into grids 600if grids are to be incorporated into PA's 500. In nesting mode, PGSU1560 simultaneously picks up pallets 502 from first end 1644 of PC 1640,out of grids 600 if girds 600 were incorporated in PA's 500, andtranslates pallets 502 and places them on pallet stacks 1507 at secondend 1528 of pallet stack conveyor 1517. If grids 600 were incorporatedin PA's 500, PGSU 1560 then simultaneously picks up grids 600 from firstend 1644 of PC 1640, and translates grids 600 and places them on gridstacks 1542 at second end 1547 of grid stack conveyor 1540.

PAGTU Embodiment 2

FIGS. 74A-F are perspective views of a second embodiment of PAGTU 7800in various PA lifting states. PAGTU second embodiment 7800 differs fromPAGTU first embodiment 4000 by its PA lifting technique, which is athree-member (including fork) arm 7811 that articulates in a verticalplane, providing fork lift as well as fork extension. PAGTU secondembodiment 7800 travels on a pair of recirculating tracks 7810 and turnsvia a turntable 7812 to avert bed-damaging track skid steering typicalof tracked vehicles. PAGTU second embodiment 7800 incorporates swiveljoints with associated servo drives at its fork's heel and between thetrack and main carriages, both providing rotation about vertical axes.Another servomotor-driven swivel joint 7813, with its axis of rotationparallel to and centered proximally above fork tines, provides forkroll. Collectively these joints provide for “universal” movement offork, accommodating undulating beds and driveways on which PAGTU secondembodiment 7800 and PATT 1200 must operate and interact. Hydraulic,electric, or equivalent servo devices suffice for driving PAGTU secondembodiment 7800, as in PAGTU first embodiment 4000.

PAGTU Embodiment 3

FIG. 75 is perspective underside view of a third embodiment of PAGTU7900 in a mid-elevation PA lifting state. PAGTU third embodiment 7900differs from PAGTU second embodiment 7800 simply by its fixedrubber-tired drive in place of the tracks of PAGTU second embodiment7800. This allows for a larger turntable 7912, rendering PAGTU thirdembodiment 7900 more stable on utilizing such device for turning.

PAFTU Embodiment 2

FIG. 76 is perspective overhead view of a second embodiment of PAFTU6000. PAFTU second embodiment 6000 differs from PAFTU first embodiment1100 simply by its vertical plane-residing servo-driven pantograph forkextension mechanism 6010. This arrangement enables PAFTU secondembodiment 6000 to require less bed space for maneuvering into and outof engagement with a PA, relative to PAFTU first embodiment 1100.Hydraulic, electric, or equivalent servo devices suffice for drivingPAFTU second embodiment 6000, as in PAFTU first embodiment 1100.

1-20. (canceled)
 21. A containerized plant array stand-alone supportstructure comprising: a substantially horizontal upper wall portion,wherein the upper wall portion is contoured into a horizontal planararray of mutually contiguous, downwardly converging funnel segments;wherein each funnel segment of the horizontal planar array is associatedwith a container receptacle extending downward from the upper wallportion and concentric with a corresponding funnel segment, and whereinthe segment incorporates at least one liquid overflow drainage passageproximal to the container receptacle; and wherein each of the containerreceptacles includes: at least one substantially upward-facing sealingsurface for providing a seal between the container receptacle and acontainer, at least one side wall, wherein the at least one verticalside wall is tapered, a substantially horizontal bottom wall comprisingat least one upward recess, wherein a bottom perimeter of the at leastone container receptacle side wall is coupled along a perimeter of thebottom wall, an open upper end, at least one receptacle liquid drainagepassage, and at least one containerized plant lifting tool access holeextending through an uppermost wall of the at least one upward recess,wherein the containerized plant lifting tool access hole is elevatedhigher from the bottom wall relative to the at least one receptacleliquid drainage passage, and wherein the at least one containerizedplant lifting tool access hole is oriented substantially beneath asection of at least one upward recess in a bottom wall of a containerwhen installed in the container receptacle.